Arm prosthetic device

ABSTRACT

A system for powering a prosthetic arm is disclosed. The system includes at least one internal battery located in the prosthetic arm, at least one external battery connected to the prosthetic arm, and a master controller configured to connect either the at least one internal battery or the at least one external battery to a power bus to power the prosthetic arm.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional 62/292,611, filedFeb. 8, 2016 and entitled Arm Prosthetic Device which is herebyincorporated by reference herein in its entirety.

This application is a Continuation-in-Part of U.S. patent applicationSer. No. 15/198,929, filed Jun. 30, 2016, and entitled Arm ProstheticDevice, which is a Continuation of U.S. patent application Ser. No.13/566,736, filed Aug. 3, 2012, and entitled Arm Prosthetic Device,which is now U.S. Pat. No. 9,381,099, issued Jul. 5, 2016, which is aContinuation-In-Part of U.S. patent application Ser. No. 13/088,063,filed Apr. 15, 2011, and entitled Arm Prosthetic Device, which is nowU.S. Pat. No. 8,979,943 issued Mar. 17, 2015, which is also aContinuation-In-Part of U.S. patent application Ser. No. 12/706,609,filed Feb. 16, 2010, and entitled Arm Prosthetic Device, now U.S. Pat.No. 8,449,624, issued May 28, 2013, which claims priority to U.S.Provisional Patent Application Ser. No. 61/168,786, filed Apr. 13, 2009,and entitled Arm Prosthetic Device, and is a Continuation-In-Part ofU.S. patent application Ser. No. 12/027,141, filed Feb. 6, 2008, andentitled Arm Prosthetic Device, now U.S. Pat. No. 9,114,028, issued Aug.25, 2015, which claims priority to U.S. Provisional Patent ApplicationSer. No. 60/899,833, filed Feb. 6, 2007, and entitled Arm ProstheticDevice, and U.S. Provisional Patent Application Ser. No. 60/963,639,filed Aug. 6, 2007, and entitled Arm Prosthetic Device, each of which ishereby incorporated by reference herein in its entirety.

U.S. application Ser. No. 13/566,736, filed Aug. 3, 2012 and entitledArm Prosthetic Device, which is now U.S. Pat. No. 9,381,099, issued Jul.5, 2016 also claims priority from U.S. Provisional Patent ApplicationSer. No. 61/542,928, filed Oct. 4, 2011, and entitled Arm ProstheticDevice, U.S. Provisional Patent Application Ser. No. 61/551,119, filedOct. 25, 2011, and entitled Arm Prosthetic Device, and U.S. ProvisionalPatent Application Ser. No. 61/604,950, filed Feb. 29, 2012, andentitled Arm Prosthetic Device, each of which is also herebyincorporated by reference herein in its entirety.

STATEMENT OF GOVERNMENT INTEREST

This invention was made with Government support under Contract NumberW911NF-09-C-0035 awarded by the U. S. Army RDECOM ACQ CTR. TheGovernment has certain rights in the invention.

TECHNICAL FIELD

The present development relates to mechanical and medical devices and,more particularly, to prosthetic devices. More particularly, thedevelopment utilizes mechanical structure and user or motor stimuli tooperate a prosthesis similarly to a human limb.

BACKGROUND INFORMATION

Existing prosthetic arms have limited movement for the user. Further,there are limited options for those patients who have lost their entirearm, shoulder to hand. Also, hand portions of existing prosthetic armsgive the user, in many instances, one degree of movement. These knownprosthetic devices provide limited capability with respect to, amongstother things, finer tasks.

Accordingly, there is a need for a prosthetic arm that replaces an armfrom shoulder to hand and that has increased degrees of freedom. Thereis also a need for a prosthetic hand that moves in a realistic manner.

SUMMARY

In accordance with one aspect of the present invention, a system forpowering a device is disclosed. The system includes at least oneinternal battery located in a device, at least one external batteryconnected to the device, and a master controller configured to connecteither the at least one internal battery or the at least one externalbattery to a power bus to power the device.

Some embodiments of this aspect of the present invention include one ormore of the following, wherein the system further includes wherein theat least one external battery further includes a keying feature. Whereinthe system further includes a battery charger for charging the at leastone external battery.

Wherein the battery charger is configured to accommodate at least twoexternal batteries. Wherein the system includes at least two externalbatteries. Wherein the external batteries include built-in circuits formeasuring state-of-charge. Wherein the system further includes a holsterconfigured to accept and secure the at least one external battery.Wherein the holster further includes a power button. Wherein the atleast one external battery powers the device. Wherein the at least oneinternal battery is rechargeable. Wherein the at least one externalbattery is rechargeable. Wherein the system further includes at leastone AC adapter. Wherein the AC adapter charges the internal battery.Wherein the master controller is configured to recharge the internalbattery using the at least one external battery. Wherein the systemfurther includes wherein the master controller is configured todetermine the capacity of the at least one internal battery, and whenthe capacity of the at least one internal battery is below a threshold,and determine whether to charge the internal battery using an AC adapteror from the at least one external battery. Wherein the master iscontroller is configured to determine when to switch from receivingpower from the internal battery to receiving power from the at least oneexternal battery. Wherein the master controller is configured todetermine the capacity of the internal battery, and when the capacity ofthe internal battery is below a threshold, determining whether to chargethe internal battery using an AC adapter or from the at least oneexternal battery. Wherein the master controller is configured todetermine the external battery has been disconnected from a holster, andswitch to use the internal battery to power the bus. Wherein the mastercontroller is configured to

determine if an external battery is connected to the system, and if anexternal battery is connected to the system, connecting the externalbattery to the power bus, and disconnecting the internal battery fromthe power bus. Wherein the master controller is configured to determinethe external battery remaining capacity is below a predeterminedthreshold, and command the internal battery to switch to power the bus.Wherein the master controller is configured to power the device using afirst external battery, disconnect the first external battery from thedevice, connect an internal battery to a power bus to power the device,connecting an AC adapter to the device, charging the internal batteryusing the AC adapter, disconnecting the AC adapter from the device,connecting the first external battery to the device, and charging theinternal battery using the first external battery. Wherein the mastercontroller is configured to power the device using a first externalbattery, disconnect the first external battery from the device,

connect an internal battery to a power bus to power the device, connectan AC adapter to the device, and charge the internal battery using theAC adapter. Wherein the master controller is configured to power thedevice using a first external battery, disconnect the first externalbattery from the device, connect an internal battery to a power bus topower the device, connect a second external battery to the device,disconnect the internal battery from the power bus, and

connect the second external battery to the power bus. Wherein the mastercontroller is configured to power the device using a first externalbattery, determine that the first external battery is disconnected fromthe device, and

turn the internal interface circuit on to power the device using aninternal battery.

Wherein the master controller is configured to monitor the capacity ofan internal battery, determine the capacity of an external battery,determine whether the internal battery capacity is less than apredetermined threshold, and if the internal battery capacity is lessthan a predetermined threshold, and the external battery capacity ifabove a predetermined threshold, charging the internal battery using theexternal battery. Wherein the master controller is configured todetermine if an external battery is connected to the device, if not, themaster controller allowing the internal battery to power the bus, if anexternal battery is connected to the device, determine the capacity ofthe external battery, if the capacity exceeds a predetermined threshold,disconnecting the internal battery from powering the bus, and connectthe external battery to power the bus. Wherein the master controller isconfigured to determine if an external battery is connected to thedevice, if not, the master controller allowing the internal battery topower the bus, if an external battery is connected to the device,disconnect the internal battery from powering the bus and connect theexternal battery to power the bus.

In accordance with one aspect of the present invention, a method forpowering a device is disclosed. The method includes determining thetotal capacity of the installed batteries in a device; and if the totalcapacity is below a predetermined threshold, then alerting a user thatthe total capacity is below a threshold.

In accordance with one aspect of the present invention, a method forpowering a device is disclosed. The method includes determining if anexternal battery is connected to the device, if not, the mastercontroller allowing the internal battery to power the bus, if anexternal battery is connected to the device, disconnecting the internalbattery from powering the bus, and connecting the external battery topower the bus.

In accordance with one aspect of the present invention, a method forpowering a device is disclosed. The method includes determining if anexternal battery is connected to the device, if not, the mastercontroller allowing the internal battery to power the bus, if anexternal battery is connected to the device, determining the capacity ofthe external battery, if the capacity exceeds a predetermined threshold,disconnecting the internal battery from powering the bus, and connectingthe external battery to power the bus.

In accordance with one aspect of the present invention, a method forpowering a device is disclosed. The method includes monitoring thecapacity of an internal battery, determining the capacity of an externalbattery, determining whether the internal battery capacity is less thana predetermined threshold, and

if the internal battery capacity is less than a predetermined threshold,and the external battery capacity if above a predetermined threshold,charging the internal battery using the external battery.

In accordance with one aspect of the present invention, a method forpowering a device is disclosed. The method includes determining anexternal battery has been disconnected from a holster, and themicrocontroller switching to use an internal battery of the device topower the bus.

In accordance with one aspect of the present invention, a method forpowering a device is disclosed. The method includes powering the deviceusing a first external battery, determining that the first externalbattery is disconnected from the device, and turning the internalinterface circuit on to power the device using an internal battery.

In accordance with one aspect of the present invention, a method forpowering a device is disclosed. The method includes powering the deviceusing a first external battery, disconnecting the first external batteryfrom the device, connecting an internal battery to a power bus to powerthe device, connecting a second external battery to the device,disconnecting the internal battery from the power bus, and connectingthe second external battery to the power bus.

In accordance with one aspect of the present invention, a method forpowering a device is disclosed. The method includes powering the deviceusing a first external battery, disconnecting the first external batteryfrom the device, connecting an internal battery to a power bus to powerthe device, connecting an AC adapter to the device, and charging theinternal battery using the AC adapter.

In accordance with one aspect of the present invention, a method forpowering a device is disclosed. The method includes powering the deviceusing a first external battery, disconnecting the first external batteryfrom the device, connecting an internal battery to a power bus to powerthe device, connecting an AC adapter to the device, charging theinternal battery using the AC adapter, disconnecting the AC adapter fromthe device, connecting the first external battery to the device; andcharging the internal battery using the first external battery.

According to some aspects of the present invention, a battery system isdisclosed. The system includes at least one electronic device having ahousing, at least one rechargeable internal battery located inside theelectronic device housing, and at least one external battery locatedoutside the electronic device housing, wherein the at least one externalbattery charges the at least one internal battery.

It is one aspect of the present device to provide a prosthetic devicethat will allow the user improved range of motion, improved tactilecapabilities, increased comfort for the user, and decreased reliance onmanual positioning of the prosthesis.

According to some aspects of the present invention, a compound motionassembly for providing a two-axis compound motion through apre-determined path includes an input member and an output membermoveably coupled to the input member. Actuation of the compound motionassembly generates movement of the output member relative to the inputmember along a compound motion path having motion about at least twoaxes. In some embodiments, the compound motion assembly includes a drivearrangement for controlling movement of the output member relative tothe input member. In these embodiments, the rate of motion about eachaxis may vary as the drive arrangement is actuated at a constant rate.

According to some embodiments, the output member may be moveably coupledto the input member through at least a first joint having a first axisand a second joint having a second axis, the first and second jointsbeing connected in series. The compound motion assembly may include apath member that is fixedly coupled to the input member and has a fixedpath profile formed therein defining the compound motion path. Afollower member may be coupled to the output member and engaging thefixed path profile of the path member such that pivotal movement of theoutput member relative to the input member about both the first axis andthe second axis is generated as the follower member moves along thepre-determined path. In some embodiments, the drive arrangement maydrive the compound motion assembly through one of the first or secondjoints to cause movement of the output member.

According to some aspects of the present invention, a prosthetic limbsegment has a housing with an input interface and an output interfacethat are moveable with respect to one another and a motorized drive foreffecting movement of at least one of the output interface or the inputinterface. The prosthetic limb segment also includes a controllerdisposed within the housing for controlling the motorized drive and alsofor communicating with and controlling at least a second motorized driveof at least a second prosthetic limb segment.

According to some embodiments, the prosthetic limb segment may include auser interface integrally formed in the housing and in communicationwith the controller. The user interface may include a status indicatorfor displaying information from the controller. In some embodiments, thestatus indicator may have one or more LEDs for displaying informationfrom the controller. In some embodiments, at least a portion of the LEDsare arranged in an array. In some embodiments, the user interfaceincludes at least one input member for providing a signal to thecontroller. The user interface may include a protective cover, which maybe flexible and may include at least a portion that is translucent toallow light from an LED disposed beneath the protective covertherethrough.

According to some aspects of the present invention, a safety mechanismfor a prosthetic device having at least one motorized drive and acontroller for controlling the motorized drive is provided. The safetymechanism includes an actuator electrically coupled in parallel with thecontroller between the motorized drive and a power source so thatactuation of the actuator supplies power to the motorized drivebypassing the controller and actuates the motorized drive until itreaches a safe position.

According to some embodiments, the safety mechanism may include anactuator that has at least two switches coupled to actuatesimultaneously and electrically coupled in parallel so that actuation ofonly one switch of the at least two switches is sufficient to actuatethe motorize drive, thereby providing redundancy. In some embodiments,the actuator is electrically coupled in parallel with the controllerbetween the power source and a plurality of motorized drives such thatactuation of the actuator supplies power to the plurality of motorizeddrives and actuates each motorized drive until it reaches a safeposition.

The same compliance method is applied to the MRP drive, allowing it tostore elastic energy.

These aspects of the invention are not meant to be exclusive and otherfeatures, aspects, and advantages of the present invention will bereadily apparent to those of ordinary skill in the art when read inconjunction with the appended claims and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will bebetter understood by reading the following detailed description, takentogether with the drawings wherein:

FIG. 1 is a perspective view of one embodiment of a prosthetic armapparatus according to the present invention;

FIG. 2 is an exploded view of the prosthetic arm apparatus of FIG. 1;

FIG. 3 is a rear view of a shoulder abductor of the prosthetic armapparatus of FIG. 1 according to the present invention;

FIG. 4 is a front view of the shoulder abductor of FIG. 3;

FIG. 5 is a side view of the shoulder abductor of FIG. 3;

FIG. 6 is a perspective view of the shoulder abductor of FIG. 3;

FIG. 7 is an exploded perspective view of the shoulder abductor of FIG.6;

FIG. 8 is a perspective view of a shoulder flexion assembly of theprosthetic arm apparatus of FIG. 1 according to the present invention;

FIG. 9 is a reverse perspective view of the shoulder flexion assembly ofFIG. 8;

FIG. 10 is an exploded perspective view of the shoulder flexion assemblyof FIG. 8;

FIG. 11 is a cross-sectional perspective view of the shoulder flexionassembly of FIG. 8;

FIG. 12 is a top view of a non-backdriving clutch according to thepresent invention;

FIG. 13 is a perspective view of a fully assembled compliancesubassembly of the shoulder flexion assembly of FIG. 8;

FIG. 14 is a perspective view of the bottom portion of the compliancesubassembly of FIG. 13;

FIG. 15 is a perspective view of the top portion of the compliancesubassembly of FIG. 13;

FIG. 16 is a perspective view of a humeral rotator of the prosthetic armapparatus of FIG. 1 according to the present invention;

FIG. 17 is a cross-sectional perspective view of the humeral rotator ofFIG. 16;

FIG. 18 is a perspective view of an elbow flexion assembly of theprosthetic arm apparatus of FIG. 1 according to the present invention;

FIG. 19 is a cross-sectional perspective view of one embodiment of theelbow flexion 15 assembly shown without the radial mount;

FIG. 20 is a cross-sectional perspective view of the elbow flexionassembly shown with the radial mount;

FIG. 21A is a perspective view showing the compliance subassembly of theelbow flexion assembly of FIG. 19;

FIG. 21B is an exploded perspective view of a compliance subassemblyaccording to another embodiment of the present invention;

FIG. 22 is an exploded perspective view of the elbow flexion assembly ofFIG. 18;

FIG. 23 is a perspective view of a wrist rotator of the prosthetic armapparatus of FIG. 1 according to the present invention;

FIG. 24 is a cross-sectional perspective view of the wrist rotator ofFIG. 23;

FIG. 25 is a perspective view of a wrist flexion assembly and a handcontrol module of the prosthetic arm apparatus of FIG. 1 according tothe present invention;

FIG. 26 is a rear perspective view of the wrist flexion assembly andhand control module of FIG. 25;

FIG. 27 is a cross-sectional perspective view of the wrist flexionassembly and hand control module of FIG. 25;

FIG. 28 is a perspective view of a wrist assembly output arm of FIG. 25;

FIG. 29 is a side view of a hand assembly of the prosthetic armapparatus of FIG. 1 according to one embodiment;

FIG. 30 is a front view of one embodiment of the hand assembly of FIG.29;

FIG. 31 is a perspective view of one embodiment of the hand assembly ofFIG. 29 showing an index finger tensioner assembly;

FIG. 32 is a cross-sectional view of one embodiment of the hand assemblyof FIG. 29 showing an MRP tensioner assembly;

FIG. 33 is a front cross-sectional view of one embodiment of the MRPdifferential drive of FIG. 30;

FIG. 34 is a front cross-sectional view of one embodiment of thumbdifferential drives of FIG. 30;

FIG. 35 is a side view of one embodiment of the hand assembly of FIG. 30showing a tactile feedback sensor according to the present invention;

FIG. 36 is a perspective view of one embodiment of the tactile feedbacksensor and a feedback actuator of the prosthetic arm apparatus of FIG.1;

FIG. 37 is a perspective view of another embodiment of the tactilefeedback sensor and feedback actuator of the prosthetic arm apparatus ofFIG. 1 according to the present invention;

FIG. 38 is an exploded view of a portion of the hand showing anotherembodiment of the index and MRP fingers drives;

FIG. 39 is an exploded view of another embodiment of the hand;

FIG. 40 is a perspective view of another embodiment of the hand;

FIG. 41 is a perspective cutaway view of the hand;

FIG. 42A shows an embodiment of an integrated shoulder unit according toan embodiment of the present invention;

FIG. 42B is a partial cutaway view of the integrated shoulder unit ofFIG. 42A in an inactuated state;

FIG. 42C is a partial cutaway view of the integrated shoulder unit ofFIG. 42A in an actuated state;

FIG. 43 is a cross sectional view of another embodiment of an integratedshoulder unit according to the present invention;

FIG. 44 is a cross sectional view of another embodiment of theintegrated shoulder unit of FIG. 43;

FIG. 45 is a top view of a shoulder abductor and shoulder flexionassembly according to another embodiment of the present invention;

FIG. 46 is a side plane view of shoulder flexion assembly mount of theshoulder abductor of FIG. 45;

FIG. 47A is a side cross-sectional view of an embodiment of a shoulderfree swing system according to the present invention;

FIG. 47B is a front cross-sectional view of the shoulder free swingsystem of FIG. 47A when disengaged;

FIG. 47C is a front cross-sectional view of the shoulder free swingsystem of FIG. 47C when engaged;

FIG. 48A is a side perspective view of a shoulder free swing systemaccording to another embodiment of the present invention;

FIG. 48B is a side cross-sectional view of the shoulder free swingsystem of FIG. 48A;

FIG. 49 is a cross-sectional view of one embodiment of a rotatoraccording to the present invention;

FIG. 50 is a side view of one embodiment of a flexion assembly accordingto the present invention;

FIG. 51 is a front view of the flexion assembly of FIG. 50;

FIG. 52 is a perspective view of another embodiment of a wrist flexionassembly according to the present invention;

FIG. 53 is a partially exploded perspective view of the wrist flexionassembly of FIG. 52;

FIG. 54 is a top cross-sectional view of the wrist flexion assembly ofFIG. 52;

FIG. 55 is a top cross-sectional view of the wrist flexion assembly ofFIG. 52;

FIG. 56 is a cross-sectional view of another embodiment of a wristflexion assembly according to the present invention;

FIG. 57A is a partial cross-sectional view of another embodiment of thenon-backdriving clutch of FIG. 12;

FIG. 57B is a cross-sectional view of another embodiment of thenon-backdriving clutch of FIG. 12;

FIG. 57C is a cross-sectional view of a combination gearbox includingthe non-backdriving clutch of FIG. 57B;

FIG. 58A is an exploded perspective view of an embodiment of the handassembly according to the present invention;

FIG. 58B is an exploded perspective view of an embodiment of an indexfinger structure of FIG. 58A;

FIG. 59 is a perspective view of a compliance assembly according to anembodiment of the present invention;

FIG. 60A is a side view of a breakaway mechanism according to anembodiment of the present invention;

FIG. 60B is a front cross-sectional view of the breakaway mechanism ofFIG. 60A;

FIG. 61A-63B are various views of another embodiment of a breakawaymechanism according to the present invention;

FIG. 64 is a front view of a magnetic sensor according to someembodiments of the present invention;

FIG. 65 is a side cross-sectional view of another embodiment of amagnetic sensor according to the present invention;

FIG. 66 is a cross-sectional view of a hand assembly according to anembodiment of the present invention;

FIG. 67 is a front view of a hand assembly cosmesis according to anembodiment of the present invention;

FIG. 68A is a front view of an embodiment of the cosmesis of FIG. 67with removable finger portions;

FIG. 68B is a cross-sectional view of an embodiment of a fingerstructure cosmesis of FIG. 68A;

FIG. 69 is a perspective view of another embodiment of the cosmesis ofFIG. 67;

FIG. 70 is a side perspective view of another embodiment of a cosmesisaccording to the present invention;

FIG. 71 is a perspective view of a prosthetic arm apparatus having atemperature sensor according to an embodiment of the present invention;

FIG. 72A is a side view of a thumb structure according to an embodimentof the present invention;

FIG. 72B is a side cross-sectional view of the thumb structure of FIG.72A;

FIG. 72C is a side cross-sectional view of the thumb structure of FIG.72A under a load;

FIG. 73 is a side cross-sectional view of a thumb structure according toanother embodiment of the present invention;

FIG. 74 is a top view of a humeral rotator and an elbow flexion assemblyaccording to another embodiment of the present invention;

FIG. 75A is a perspective view of a prosthetic arm apparatus havingsafety features according to an embodiment of the present invention;

FIG. 75B is a perspective view of a prosthetic arm apparatus havingsafety features according to an embodiment of the present invention;

FIG. 75C is a perspective view of the wrist rotator according to anembodiment of the present invention;

FIG. 75D is a side perspective view of the wrist rotator and atransradial mount according to an embodiment of the present invention;

FIG. 75E is a front perspective view of the wrist rotator and atransradial mount of FIG. 75D;

FIG. 76 is a perspective view of a wrist flexion assembly according toanother embodiment of the present invention;

FIG. 77 is a perspective view of a first cam bearing of the wristflexion assembly of FIG. 76;

FIG. 78 is a perspective view of a second cam bearing of the wristflexion assembly of FIG. 76;

FIG. 79A is a perspective view of the wrist flexion assembly of FIG. 76in a first position;

FIG. 79B is a perspective view of the wrist flexion assembly of FIG. 76in a second position;

FIG. 79C is a perspective view of the wrist flexion assembly of FIG. 76in a third position;

FIG. 80 is a line graph of a fixed movement path of the wrist flexionassembly of FIG. 76;

FIG. 81 is a side perspective view of a compound motion assemblyaccording to an embodiment of the present invention;

FIG. 82 is a top perspective view of an embodiment of a fixed pathmember of the compound motion assembly of FIG. 81;

FIG. 83 is a top view of the fixed path member of FIG. 82;

FIG. 84 is a side view of the compound motion assembly of FIG. 81;

FIG. 85 is a cross sectional view of the compound motion assembly ofFIG. 84;

FIG. 86 is an exploded perspective view of the compound motion assemblyof FIG. 84;

FIG. 87 is a side perspective view of a compound motion assembly of FIG.81 having the hand assembly attached thereto;

FIGS. 88A-88F are side perspective views of the compound motion assemblyof FIG. 81 at various positions along its full range of motion;

FIG. 89 is a line graph of a compound motion path of the compound motionassembly of FIG. 81;

FIG. 90 is a side perspective view of an embodiment of an antennaaccording to the present invention;

FIG. 91 is a partially exploded view of the antenna of FIG. 90;

FIG. 92 is a schematic view of the antenna matching network of FIG. 90;

FIG. 93 is a top perspective view of an embodiment of another antennaaccording to the present invention;

FIG. 94 is a schematic view of the antenna branching network of FIG. 93;

FIG. 95 is a side perspective view of another embodiment of a compoundmotion assembly according to the present invention;

FIG. 96 is a side perspective view of another embodiment of a compoundmotion assembly according to the present invention;

FIG. 97 is a top view of one embodiment of a socket preparationdevice/frame;

FIGS. 98A-98C are various views of one embodiment of a prostheticmounting device;

FIGS. 99A-99D show various views of the socket preparation devicetogether with a prosthetic mounting device, according to one embodiment;

FIGS. 100A-100F are various views of a shoulder flexor-abductoraccording to one embodiment;

FIGS. 101A-101D are various views of the brake mechanism according toone embodiment;

FIGS. 102A-102E are various views of the abductor potentiometer sensorsystem according to one embodiment;

FIGS. 103A-103C are various views of the wrist rotator sensor accordingto one embodiment;

FIGS. 104A-104B are various views of the wrist according to oneembodiments, including a wrist position sensor;

FIG. 105 is one embodiments of a battery interface;

FIG. 106 shows one embodiment of an external battery and one embodimentof a holster;

FIG. 107 shows one embodiment of a charger and one embodiment of twoexternal batteries;

FIG. 108 is a diagram of one embodiment of the battery system;

FIG. 109 is a diagram of one embodiment of the internal batteryinterface;

FIG. 110 is a diagram of one embodiment of the internal batteryinterface;

FIG. 111 is a diagram of one embodiment of the external batteryinterface;

FIG. 112 is a diagram of one embodiment of the external batteryinterface;

FIG. 113 is a diagram of one embodiment of the external battery andinternal battery system;

FIGS. 114A-114F are various views of the caliper braking systemaccording to one embodiment;

FIGS. 115A-115B are various views of the index pivot system according toone embodiment; and

FIGS. 116A-116B are various views of one embodiment of a hand includingan embodiment of a compliance assembly.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

Referring to FIGS. 1 and 2, a prosthetic arm apparatus 10 for attachmentto a shoulder of a shoulder disarticulated amputee includes a pluralityof segments, including a shoulder abductor 12, a shoulder flexionassembly 14, a humeral rotator 16, an elbow flexion assembly 18, a wristrotator 20, a wrist flexion assembly 22, and a hand assembly 24. Theprosthetic arm apparatus 10, in the exemplary embodiment, has thedimensions and weight of a female arm of a fiftieth percentile, so thatmany different users may comfortably use the prosthetic arm apparatus10. As should be understood by those skilled in the art, the prostheticarm apparatus 10 may be constructed to larger or smaller dimensions ifdesired. The prosthetic arm apparatus 10 may be controlled by a controlsystem (not shown), such as the various control systems described inU.S. patent application Ser. No. 12/027,116, filed Feb. 6, 2008, U.S.patent application Ser. No. 12/706,575, filed Feb. 16, 2010, U.S. patentapplication Ser. No. 12/706,471, filed Feb. 16, 2010, and the U.S.patent application entitled SYSTEM, METHOD AND APPARATUS FOR CONTROL OFA PROSTHETIC DEVICE, filed on the same day as the present applicationand assigned to the same assignee, each of which is hereby incorporatedby reference in its entirety.

Referring to FIG. 3, one embodiment of the shoulder abductor 12 isshown. The shoulder abductor 12 includes a harness mount 26 forconnecting the prosthetic arm apparatus 10, shown in FIG. 1, to asupport apparatus, as the various prosthetic supports described in U.S.patent application Ser. No. 12/026,971, filed Feb. 6, 2008, U.S. patentapplication Ser. No. 12/706,340, filed Feb. 16, 2010, and the U.S.patent application entitled DYNAMIC SUPPORT APPARATUS AND SYSTEM, filedon the same day as the present application and assigned to the sameassignee, each of which is hereby incorporated by reference in itsentirety. The harness mount 26 has harness interface holes 28 that maybe used to attach the abductor 12 to a prosthetic harness (not shown) orother system for supporting the prosthetic arm apparatus 10. In theexemplary embodiment, the harness or prosthetic support apparatus mayalso be one disclosed in co-pending U.S. patent application Ser. No.12/026,971, by Altobelli, et al., entitled Dynamic Support Apparatusfiled on Feb. 6, 2008, which is hereby incorporated by reference in itsentirety.

Referring to FIG. 4, the shoulder abductor 12 also has a shoulderflexion assembly mount 30, shown according to one embodiment. Theshoulder flexion assembly mount 30 interfaces with the shoulder flexionassembly 14 to mount the shoulder flexion assembly 14 onto the shoulderabductor 12. In one embodiment, the flexion assembly mount 30 hasinterface holes 32 to facilitate connection of the shoulder flexionassembly 14 by attachment means such as bolts.

Referring to FIG. 5, the shoulder abductor 12 further includes anabductor joint 34, shown according to one embodiment. The abductor joint34 is used to pivot the shoulder flexion assembly mount 30 away from theharness mount 26 and back toward the harness mount 26.

Referring to FIGS. 6 and 7, the shoulder abductor 12 includes anabductor motor 36 to control the pivotal movement of the abductor joint34, shown in FIG. 5, both the shoulder abductor 12 and abductor motor 36shown according to one embodiment. In this embodiment, the abductormotor 36 is a brushed DC motor controlling the pivotal movement throughan abductor belt 38 connected to a worm drive 41 driving a worm wheel 39connected to an abductor harmonic drive gearing system 40.

Referring to FIGS. 8 and 9, the shoulder flexion assembly 14, in oneembodiment, has a main shoulder housing 42, with an abductor interface44 for connecting the shoulder flexion assembly 14 to the shoulderabductor 12. The shoulder flexion assembly 14 also has a humeralinterface 46 for connecting the humeral rotator 16 to the shoulderflexion assembly 14.

Referring to FIGS. 10 and 11, in one embodiment, shoulder flexion motormagnets 52 are disposed around a shaft 58 of a shoulder flexion motorrotor 54. In this embodiment, a shoulder flexion motor armature 55drives the shoulder flexion motor rotor 54, which in turn drives ashoulder flexion motor pulley 56 around a motor shaft 58. The shoulderflexion motor pulley 56 supports a shoulder flexion belt 60, which islinked between the shoulder flexion motor pulley 56 and a shoulderflexion belt-driven pulley 62. The shoulder flexion belt-driven pulley62 drives a shoulder flexion harmonic drive gearing system wavegenerator 64. A shoulder flexion harmonic drive gearing systemflexspline 66 rotates against the shoulder flexion harmonic drivegearing system wave generator 64 and a shoulder flexion harmonic drivegearing system circular spline 68, resulting in reduced speed for thejoint movement. The shoulder flexion harmonic drive gearing systemflexspline 66 is connected to the abductor interface 44, and is thusable to rotate the shoulder flexion assembly 14 in reference to theabductor interface.

Referring to FIG. 11, in one embodiment, a non-backdriving clutch 70 isdisposed inside the main shoulder housing 42. The non-backdriving clutch70 allows the prosthetic arm 10 to hold position by locking when theprosthetic arm 10 is not moving.

Referring to FIG. 11 and FIG. 12, in one embodiment, roller bearings 72line the interface between an input cage 74 and an output hex 76. When aforce is applied to the shoulder abductor interface 44, the output hex76 locks against the bearing race 78 and the roller bearings 72. Thisprevents the shoulder flexion assembly 14 from moving due to forceapplied to its output, shoulder abductor interface 44. Upon the exertionof a necessary amount of input force through the clutch input cage 74,the output hex 76 disengages and allows the shoulder flexion assembly 14to move. The clutch input cage 74 and the output hex 76 are bothconstrained by a clutch race 78. It should be understood by thoseskilled in the art, that other mechanisms could be used to preventbackdriving of the prosthetic arm 10, such as a clutch that locks in onedirection or a solenoid with brakes that engage when the solenoid ispowered. Additionally, although described in connection with theshoulder flexion assembly 14, it should be understood by those skilledin the art that the non-backdriving clutch 70 may be included in otherprosthetic joints described herein.

Referring to FIG. 13, in one embodiment, a compliance subassembly 50,shown in FIG. 11, includes a compliance reactor 80 positioned on top ofthe shoulder flexion harmonic drive gearing system circular spline 68,shown in FIG. 10, and held in place by the clamp 82. The compliancereactor 80 measures the amount of displacement in the compliancesubassembly 50 in relation to the position of a compliance sensor magnet84.

Referring to FIG. 14, in one embodiment, the interior of compliancesubassembly 50 includes series elastic elements 86. The shoulder flexionharmonic drive gearing system circular spline 68 defines the interior ofthe compliance subassembly 50 and is formed to accommodate the placementof the series elastic elements 86 around an outer diameter 87 of theshoulder flexion harmonic drive gearing system circular spline 68. Theseries elastic elements 86 are confined by the shoulder flexion harmonicdrive gearing system circular spline 68 and the clamp 82.

Referring to FIG. 15, the placement of the compliance reactor 80 inrelation to the series elastic elements 86 and reactor elements 88 isshown. In this embodiment, three reactor elements 88 are positionedaround the compliance reactor 80, equidistant to each other. One serieselastic element 86 is placed on either side of each reactor element 88.When the shoulder flexion assembly 14 is subjected to unexpected force,such as a sudden jolt or impact, the compliance reactor 80 and reactorelements 88 displace from their rest positions and compress against theseries elastic elements 86. In that way, the compliance subassembly 50attenuates the shock being transferred to the rest of the shoulderflexion assembly 14. The compliance reactor 80 may also measure theamount of displacement and compliance by measuring the movement of thecompliance reactor 80 in relation to the stationary position of thecompliance sensor magnet 84.

Referring to FIG. 16, one embodiment of the humeral rotator 16 is shown.The humeral rotator 16 includes an outer bearing carrier 90 attached tothe first control housing 92, shown in FIG. 2. The first control housing92, shown in FIG. 2, is used to connect the humeral rotator 16 to theshoulder flexion assembly 14. The inner rotational elements of thehumeral rotator are held in place by a clamp 94, which is fastened tothe outer bearing carrier 90. A humeral mount 96 passes through theclamp 94 and includes an elbow interface 98 for attaching the elbowflexion assembly 18 to the humeral rotator 16.

FIG. 17 shows a cross-sectional view of the humeral rotator 16. Ahumeral motor armature 100 drives a humeral motor rotor 102 havinghumeral magnets 104 disposed on its surface. The lower portion of themotor rotor 102 engages a humeral harmonic drive gearing system wavegenerator 106. A humeral harmonic drive gearing system flexspline 108rotates with the humeral harmonic drive gearing system wave generator106 against the humeral harmonic drive gearing system circular spline110, resulting in a speed of rotation reduction as the humeral harmonicdrive gearing system flexspline 108 causes the humeral mount 96 to move.Bearings 111 and 113 support the humeral motor rotor 102. Bearings 112support the harmonic drive gearing system components 106, 108, 110. Abearing support 114 caps the outer bearing carrier 90 between the outerbearing carrier 90 and the first control housing 92, shown in FIGS. 16and 2, respectively.

Still referring to FIG. 17, the one embodiment, a humeral potentiometer116 of the humeral rotator 16, measures the rotational displacement of ahumeral potentiometer shaft 118 that rotates proportionately to thehumeral mount 96.

Referring to FIG. 18, the elbow flexion assembly 18 includes an elbowjoint 120 and a radial mount 122. The elbow joint 120 includes a slot124 into which the elbow interface 98 of the humeral rotator is insertedto facilitate connection of the elbow flexion assembly 18 to the humeralrotator 16. The radial mount 122 provides a second electronics housing126, in which an ACM stack 128 is located. “ACM” as used herein refersto Arm Control Module. The radial mount 122 includes a wrist interface130, for attachment of the wrist rotator 20.

In some embodiments, the ACM stack 128 may be integrated into the wristrotator 20, as will be discussed in greater detail below. Integratingthe ACM stack 128 into the wrist rotator may be advantageous since thewrist rotator 20 is likely to be present in prosthetic arms foressentially all types of amputees, whereas the elbow flexion assembly 18may not be present, such as in a prosthetic arm for a transradialamputee.

Referring to FIG. 19, the elbow joint 120 includes an elbow motorarmature 132 that drives an elbow motor rotor 134. Elbow magnets 136 aredisposed at one end of the motor rotor 134, and the opposing end of themotor rotor 134 has a sun gear 138. As the motor armature 132 drives thesun gear 138, the sun gear 138 in turn drives four planetary gears 140positioned equidistant from each other around the sun gear 138. The fourplanetary gears 140 in turn react against a ring gear 142, giving theelbow flexion assembly 18 a first stage of speed reduction through anelbow harmonic drive gearing system wave generator 148 which also actsas the planet carrier. The elbow harmonic drive gearing system wavegenerator 148 powers the elbow harmonic drive gearing system flexspline146, which drives against the elbow harmonic drive gearing systemcircular spline 144, giving the elbow flexion assembly 18 a second stageof reduction. The elbow harmonic drive gearing system flexspline 146then drives the motion of the elbow flexion assembly 18. Bearings 150and crossed roller bearings 152 support the outer perimeter of the elbowflexion assembly 18. Although described with both a planetary gearsystem and an elbow harmonic drive gearing system, the elbow flexionassembly 18 could be controlled solely by a harmonic drive gearingsystem by changing the gear reduction ratio.

In various embodiments, it may be desirable to avoid having to performadditional measurement by using the measurement in the complianceprocess. One example includes, in various embodiments, where theplanetary gears may be used for compliance and measurement of load.

Referring to FIG. 20, in the embodiment shown, the radial mount 122 isstructurally fixed to the elbow joint 120, such that when the elbowjoint is actuated, the radial mount 122 moves.

Referring to FIG. 21A, an elbow compliance subassembly 154 isincorporated into the elbow flexion assembly 18. A plurality of arms 156extends from the center portion of the elbow compliance subassembly 154.Each arm 156 has an elbow series elastic element 158 disposed on eitherside of the arm 156. Similar to the shoulder flexion assembly 14, if theelbow flexion assembly 18 is subject to a torque, the elbow compliancesubassembly 154, with its series elastic elements 158, is capable ofabsorbing the shock attenuating the torque magnitude through the rest ofthe elbow flexion assembly 18.

Referring to FIG. 21B, wherein like numerals represent like elements, insome embodiments, the elbow compliance assembly 1154 may include acarrier having a magnet (not shown) disposed thereon and having acarrier top 1838 and a carrier bottom 1840 that connect to one anotherto surround the elbow harmonic drive gearing system circular spline 1144and that interface with a compliance grounding member 1842. The carriertop 1838 and carrier bottom 1840 to restrict movement of the elbowharmonic drive gearing system circular spline 1144, thereby allowing thecircular spline 1144 to operate substantially as discussed above todrive the elbow flexion assembly 18, shown in FIG. 18. The carrierbottom 1840 includes clips 1844 located around its periphery thatslidably engage corresponding compliance shafts 1846 of the compliancegrounding member 1842 to connect the carrier to the compliance groundingmember 1842. Each clip 1844 is positioned on a compliance shaft 1846between two compliance springs 1848 that inhibit sliding movement of theclips 1844 relative to the shafts 1846. The compliance springs 1848 arepreferably formed from metal and, in some embodiments, each spring 1848may include a plurality of stacked spring washers. In operation, as theelbow harmonic drive becomes loaded, the clips 1844 of the carrier slideon the compliance shafts 1846 and load the compliance springs 1848,which deflect in proportion to the load. A sensor (not shown) measuresthe displacement of the magnet (not shown), thereby providing ameasurement of the torque carried by the elbow harmonic drive and,therefore, the elbow flexion assembly 18, shown in FIG. 18. The elbowcompliance assembly 1154 advantageously provides improved compliancemeasurements due to its metal springs 1848 as compared to elastomericspring designs, which have greater hysteresis. Additionally, the carrierof the elbow compliance assembly 1154 advantageously allows the circularspline 1144 to be mounted without any modifications that may reduce itsload capacity.

Referring to FIG. 22, the ACM stack 128, includes circuit boards 160connected to one another by structural standoffs 162. The structuralstandoffs 162 are constructed of a conductive material, so thatelectrical power may be passed through the circuit boards 160. Thestructural standoffs allow power to be supplied to each circuit board160 without conventional power connections.

Referring to FIG. 23, the wrist rotator 20 includes a wrist outerbearing carrier 164, a wrist clamp 166, a wrist potentiometer 168, anelbow interface 170, and a wrist flexion assembly interface 172.

Referring to FIG. 24, movement of the wrist rotator 20 is controlled bya harmonic drive gearing system similar to that described for thehumeral rotator. A wrist rotator motor armature 174 drives a wristrotator motor rotor 176 having wrist rotator magnets 178 disposed to itssurface. The lower portion of the wrist rotator motor rotor 176integrates a wrist rotator harmonic drive gearing system wave generator180. A wrist rotator harmonic drive gearing system flexspline 182rotates with the wrist rotator harmonic drive gearing system wavegenerator 180 against a wrist rotator harmonic drive gearing systemcircular spline 184, resulting in reduction in the speed of rotation asthe wrist rotator harmonic drive gearing system flexspline 182 causesthe wrist flexion assembly interface 172 to move with respect to therest of the wrist rotator 20. Bearings 185 support the wrist rotatormotor rotor 176. Bearings 186 support the harmonic drive gearing systemcomponents 180,182, and 184.

Still referring to FIG. 24, the wrist potentiometer 168 of the wristrotator 20 is disposed at one end of a wrist shaft 188 and measures therotational displacement thereof. The wrist shaft 188 may be tubular,having an electronics channel 190 for passing electronic power andcontrols through the wrist rotator 20.

Referring to FIG. 25, the wrist flexion assembly 22 includes handcontrol module circuit boards 192, an input support structure 194, anoutput arm 196, and a hand interface 198. The input support structure194 connects the wrist rotator 20 with the wrist flexion assembly 22.The output arm 196 has positive and negative flexion, such that theoutput arm 196 is able to move in two opposite directions in referenceto the support structure 194. The hand interface 198 allows the handassembly 24 to be connected to the wrist flexion assembly 22. Referringto FIG. 26, the wrist flexion assembly 22, has wrist electricalconnections 200 for supplying power to a wrist flexion motor 202.

Referring to FIG. 27, in the embodiment shown, the wrist flexion motor202 drives a wrist flexion output gear 204, which in turn drives a wristflexion final stage-driven gear 206. A wrist flexion pivot axle 208 ofthe output arm 196 is axially disposed inside an opening defined by theinterior of the wrist flexion final stage-driven gear 206. Wrist flexionseries elastic elements 210 are disposed in the interior of the outputarm 196. Movement of the wrist flexion final stage-driven gear 206facilitates the positive and negative motion of the output arm 196. Anon-backdriving clutch 212 is disposed at one end of the wrist flexionoutput gear 204.

Referring to FIG. 28, the output arm 196 has a wrist flexion drive arm214, which is driven by the wrist flexion final stage-driven gear 206.The end of the wrist flexion drive arm 214 accommodates a wrist flexioncompliance sensor magnet 216. The wrist flexion series elastic elements210 are disposed on either side of the wrist flexion drive arm 214, andthe wrist flexion series elastic elements 210 and the drive arm 214 aresubstantially enclosed within the output arm 196. Similar to the elbowflexion assembly 18 and the shoulder flexion assembly 14, if the wristflexion assembly 22 is subjected to a force, the wrist flexion drive arm214 compresses the wrist flexion series elastic elements 210 andattenuates the force or impact through the rest of the wrist flexionassembly 22.

The following is a description of one embodiment of the hand assembly.Other embodiments of the hand assembly are described and shown elsewherein this specification. Referring to FIGS. 29 and 30 the hand assembly 24includes a hand support 218 for providing an interface for connectingthe hand assembly 24 to the wrist flexion output arm 196. The handassembly 24 also includes a thumb structure 220, an index fingerstructure 222, and an MRP structure 224 replicating a middle finger 226,a ring finger 228, and a pinky finger 230. In various embodiments, thethumb structure 220 may be driven by two thumb drives 232 that feed intoa single differential, giving the thumb structure 220 two degrees offreedom of movement. The index finger structure 222 may be driven by asingle index drive 234 and the MRP structure 224 may be driven by asingle MRP drive 236 that feeds a double differential. The MRP approachallows for an indeterminate versus determinate linkage.

Referring to FIG. 31, the index finger structure 222 (not shown) isdriven by the index drive 234 through an index drive pulley 238, anindex tensioner 240, an index tension belt 242, and an index fingerpulley 244. The index drive pulley 238 is stage driven and transfers thetorque to the index tension belt 242, which in turn rotates the indexfinger pulley 244, causing the index finger structure 222 to move. Asthe index tension belt 242 transfers the torque, one side of the indextension belt 242 tightens and the other side loosens, depending on whichdirection the index drive pulley 238 is rotated. The index tensioner 240is located between the index drive pulley 238 and the index fingerpulley 244 and the index tensioner 240 displaces in relation to thechange in load to maintain the tension of the index tension belt 242.The index tensioner 240 has one side grounded and the other side capableof displacement upon the application of a load. The index tensioner 240may instead ground the moveable side of the index tensioner 240 with aspring.

Referring to FIG. 38, in another embodiment, the index finger structure222 is driven through an index sun shaft 350, a set of index planets352, an index planet carrier 354, an index ring gear 356, and an indexdrive gear 358. The index drive 360 drives the index ring gear 356,turning the index planets 352, the turning of which causes the indexplanet carrier 354 to rotate. The index drive gear 358 is driven by theexternal teeth of the index planet carrier 354, causing the indexstructure 222 to move. Any torque transmitted by the index planetcarrier 354 will react against the index sun shaft 350 causing it torotationally displace the index spring 362 through the index springmount 364. This rotational displacement, sensed by an indexpotentiometer 366 can be used to infer the load on the index fingerstructure 222. This rotational displacement may be used to store elasticenergy and to provide the index finger structure 222 with a measure ofcompliance that may aid in gripping and with load absorption.

Referring to FIG. 31, the thumb structure 220 is mounted on a thumbsupport 246, which is driven by the two thumb differential drives 232.The thumb structure 220 has flexural cuts 248 at its base allowing thecompliant thumb structure 220 to move when a load is applied to it. Thiscompliance in the thumb structure 220 may aid in gripping and with loadabsorption, which may prevent the hand assembly 24 from damaging objects(not shown) by closing around them too quickly and forcefully.

Referring to FIG. 32, the hand assembly 24 includes an MRP drive pulley250 driven by the MRP drive 236. The MRP drive pulley 250 is connectedthrough an MRP tension belt 252 to the MRP pulley 254, enabling movementof the MRP structure 224. The MRP drive pulley 250 is stage driven andtransfers the load to the MRP tension belt 252, which in turn rotatesthe linked MRP structure 224 via the MRP pulley 254. As the MRP tensionbelt 252 transfers torque, one side of the MRP tension belt 252 tightensas the other side loosens. An MRP tensioner 256 located at one side ofthe MRP tension belt 252 displaces in relation to the change in load tomaintain the tension of the MRP tension belt 252. This also provides theMRP structure 224 with compliance to aid in gripping and with loadabsorption, which may prevent the hand assembly 24 from damaging objects(not shown) by closing around the objects (not shown) too quickly andforcefully.

Referring to FIG. 38, in another embodiment, the MRP finger structures224 are driven through an MRP sun shaft 370, a set of MRP planets 372,an MRP planet carrier 374, an MRP ring gear 376, and an MRP drive gear378. The MRP drive 380 drives the MRP ring gear 376, turning the MRPplanets 372, the turning of which causes the MRP planet carrier 374 torotate. The MRP drive gear 378 is driven by the external teeth of theMRP planet carrier 374, causing the MRP structures 224 to move. Anytorque transmitted by the MRP planet carrier 374 will react against theMRP sun shaft 370 causing it to rotationally displace the MRP spring 382through the MRP spring mount 384. This rotational displacement can beused to store elastic energy.

Referring to FIG. 33 the MRP differential drive 236 includes a main MRPdrive gear 258. The MRP drive gear 258 drives a first MRP input axle260. The first MRP input axle 260 drives a first differential idler gear259 which optionally drives a middle spur gear 262 or a differentialinterface gear 261. The middle spur gear 262 drives a middle pivot axle264. The middle finger 226 is mounted on the middle pivot axle 264 andis thus actuated by the MRP differential drive 236. The differentialinterface gear 261 drives a second MRP input axle 266. The second MRPinput axle 266 drives a second differential idler gear 263 whichoptionally drives a ring spur gear 268 or a pinky spur gear 272. Thering spur gear 268 drives a ring pivot axle 270. The ring finger 228 ismounted on the ring pivot axle 270 and is thus actuated by the MRPdifferential drive 236. The pinky spur gear 272 drives a pinky pivotaxle 274. The pinky finger 230 is mounted on the pinky pivot axle 274and is thus actuated by the MRP drive 236. While the MRP drive 236drives the middle finger 226, the ring finger 228 and the pinky finger230, the gear configuration of the first input axle 260 and the secondinput axle 266 allows independent movement for the under-actuated fingergear system of the MRP structures 224.

Referring to FIG. 41, in another embodiment of the hand, the MRPdifferential drive 236 includes an MRP drive gear 378 which drives adouble differential allowing the MRP fingers to conformably wrap aroundan object. The MRP drive gear 378 drives a first MRP input axle 400. Thefirst input axle 400 drives a first differential idler gear 402 whichoptionally drives a middle spur gear 404 or a differential interfacegear 406. The middle spur gear 404 drives a middle pivot axle 264. Themiddle finger 226 is mounted on the middle pivot axle 264 and is thusactuated by the MRP drive 236. The differential interface gear 406drives a second MRP input axle 408. The second MRP input axle 408 drivesa second differential idler gear 410 which optionally drives a ring spurgear 412 or a pinky spur gear 414. The ring spur gear 412 drives a ringpivot axle 270. The ring finger 228 is mounted on the ring pivot axle270 and is thus actuated by the MRP drive 236. The pinky spur gear 414drives a pinky pivot axle 274. The pinky finger 230 is mounted on thepinky pivot axle 274 and is thus actuated by the MRP drive 236. Whilethe MRP drive 236 drives the middle finger 226, the ring finger 228 andthe pinky finger 230, the gear configuration of the first input axle 400and the second input axle 408 allows independent movement for theunder-actuated finger gear system of the MRP structures 224.

Referring to FIG. 34 the thumb differential drives 232 control themovement of the thumb structure 220 and are driven by thumb actuators276. The thumb actuators 276 have nonbackdriving thumb clutches 278 toprevent output loads from reaching and backdriving the thumb actuators.One thumb actuator 276 drives a first thumb output drive 280 and a firstthumb output gear 282. The first thumb output gear 282 in turn drives afirst thumb transfer gear 284, which drives a fixed differential shaft286. The fixed differential shaft 286 drives one thumb differentialbevel gear 287. The second thumb actuator 276 drives a second thumboutput drive 288 and a second thumb output gear 290. The second thumboutput gear 290 drives a second thumb transfer gear 292, which drives athumb differential bevel gear 294. The two thumb differential bevelgears 287 and 294 operate the thumb structure 220 in its two degrees ofmotion.

The thumb structure 220, the index finger structure 222, and MRPstructure 224 in one embodiment are covered in silicone, which providesadditional friction and aids in gripping objects. In some embodiments,the entire hand assembly 24 may also be covered in silicone to provideadditional grip for holding objects. In other embodiments, the siliconematerial may be replaced by other compliant materials.

The hand assembly 24 is advantageous because the thumb structure 220,index finger structure 222 and MRP structure 224 provide various degreesof freedom that allow the formation of various grasps or grips.Additionally, the different drives for each of the thumb structure 220,index finger structure 222 and MRP structure 224 provide variousbeneficial characteristics to the hand assembly 24. For instance, thethumb structure 220 moves relatively slow, but with greater force thanthe index finger structure 222 and MRP structure 224. The index fingerstructure 222 moves quickly, but with less force and isnon-backdrivable. This combination of thumb structure movement and indexfinger structure movement allow the quick formation of strong handgrips. Additionally, the combination allows for a smaller index fingeractuator, which reduces size and weight of the hand assembly 24.Additionally, the index finger structure 222 and MRP structure 224 movesimilar to human fingers, which makes them look more natural and makesthem more intuitive for the user to control. The MRP structure 224provides only bulk control for gripping objects, without providing forindividual finger manipulation, since fine control is not necessary forthe MRP structure 224. Additionally, the MRP structure 224advantageously moves each finger of the MRP structure 224 with a singleactuator, eliminating excessive bulk in the hand assembly 24. Like theindex finger structure, the MRP structure 224 moves quickly with lowforce but is also non-backdrivable. Additionally, the fingers of the MRPstructure 224 are highly flexible, allowing them to grip objects ofvarying size and shape. The MRP structure 224 functionality allows theuser to grasp an object with the MRP structure 224 and thumb structure220, while allowing the user to move the index finger structure 222separately, for example, to activate a button on the object.

The various parts of the prosthetic arm apparatus 10 are, in someembodiments, constructed from plastic or magnesium. However, where morestrength and/or other material properties are desired, the parts may bemade of aluminum, titanium or steel. In other embodiments, the variousparts of the prosthetic arm may be constructed of other metals orplastics, depending on the desired characteristics, including strength,weight, compliance or other similar performance characteristics of thevarious parts.

Referring to FIG. 35, a tactile feedback sensor 296 may be positioned onthe inner side of the thumb structure 220. The tactile feedback sensor296 may be a pressure sensor, force sensor, a displacement sensor, orother similar sensor capable of providing the user with feedback.Referring to FIG. 36, the tactile feedback sensor 296 is operativelyconnected to a feedback actuator 298. The tactile feedback sensor 296may be connected to the feedback actuator 298 by either wires orwirelessly. In operation, as the user grips an object with the handassembly 24, feedback sensor 296 reads the displacement of or the forceexerted on the thumb structure 220. That reading is then sent to thefeedback actuator 298, which gives the user tactile feedback thatindicates the strength of the grip. Feedback actuator 298 may be placedon the chest of the user, located on a prosthetic support apparatus 299in an area of tactile communication with the user, or in any otherlocation capable of receiving tactile feedback, such as on a user'sresiduum 300. Referring to FIG. 37, the feedback actuator 298 may belocated on a foot controller 302 that is used to control hand assembly24.

Feedback actuator 298 may be a vibration motor, such as any vibrationmotor known in the art, placed against the skin of the user. As the usergrips an object, feedback actuator 298 begins vibrating, notifying theuser how strong the object is being gripped. As the force on ordisplacement of the tactile feedback sensor 296 changes, frequencyand/or amplitude of vibration may also change, notifying the amputee ofa changing grip. For example, if a vibrating actuator 298 is placed atthe chest of the user as in FIG. 36, the user will feel the vibration athis chest.

The feedback actuator 298 may also be placed wherever the controller forthe hand assembly 24 is located. For example, if a foot controller 302controls the hand assembly 24, the feedback actuator 298 may beincorporated into the foot controller 302. The user will then receivetactile feedback of the strength of the prosthetic grip at the samelocation where the controller is located.

The actuator 298 may also be a pressure actuator that applies pressureagainst the user's skin. For example, the actuator 298 may have a rodthat increases pressure against the amputee's skin as the hand assembly24 increases its grip on an object.

Although described with a single tactile feedback sensor 296, additionaltactile feedback sensors may be placed at other locations on the handassembly 24. For example, additional tactile feedback sensors 296 may beplaced on the index finger structure 222, the MRP structures 224, on thepalm of the hand assembly 24, or on any combination of these positionsor any other location. Each tactile feedback sensor 296 would then beoperatively connected to an associated feedback actuator 298. Multipletactile feedback sensors 296 and actuators 298 would provide moresophisticated tactile feedback of the strength of the grip, improvingthe control of the hand assembly 24.

In some embodiments, the tactile feedback sensor 296 may indicate achange in pressure or force, rather than an absolute pressure or force.For example, if the force detected by the tactile feedback sensor 296 isconstant, the feedback actuator 298 does not actuate, but if thatpressure or force increases or decreases, the actuator 298 would actuateto indicate the change in pressure or force. Additionally, althoughdescribed in terms of grip strength, the tactile feedback sensors 296and actuators 298 may provide a variety of other feedback in includingtemperature, an operational mode of the prosthetic arm 10, surfacefinish of a object, slip of an object within the hand assembly 24 or thelike.

In operation, the prosthetic arm apparatus is able to move substantiallysimilar to a human arm. Referring to FIGS. 29 and 30, starting with thehand assembly 24, the thumb structure 220, index finger structure 222,and MRP structure 224 are each driven independent of the others, andtherefore, each may be actuated without actuating the other twostructures. Both of the thumb actuators 276 control motion of the thumbstructure 220 in a direction toward or away from the center of the palmof the hand assembly 24, as shown in FIG. 34, through the miter gear 294and in a direction toward or away from the side of the palm of the handassembly 24, as shown in FIG. 34, through the lateral rotation shaft,depending upon the direction and speed of rotation of each thumbactuator 276. Thus, the thumb actuators 276, shown in FIG. 34, providethe thumb structure 220 with two degrees of freedom in the thumbstructure's movement. Coupling the two thumb actuators 276 through thedifferential described above to provide the two degrees of freedom tothe thumb structure 220 is advantageous over providing a single degreeof freedom with each actuator 276 because the torque of each actuator276 through the differential is used for movement in both degrees offreedom, which effectively doubles the torque of the thumb in eachdirection as compared to single actuators. Specifically, the indexfinger structure 222 may be actuated toward or away from the palm of thehand assembly 24, wherein the movement path is similar to that of ahuman index finger while making or releasing a fist. The middle finger226, ring finger 228, and pinky finger 230 of the MRP structure 224 areactuated by the MRP differential drive 236. Additionally, the middlefinger 226, ring finger 228, and pinky finger 230 are actuated toward oraway from the palm of the hand assembly 24, similar to the index fingerstructure 222. However, the middle finger 226, ring finger 228, andpinky finger 230 are each geared separately, such that the rate ofmovement of each is different, simulating human finger movement andmaking the hand assembly 24 more similar to a human hand thanconventional prior art prosthetic devices.

Referring to FIG. 1, the hand assembly 24 is mounted on the wristflexion assembly 22 via the hand interface 198, as shown in FIG. 25.Referring to FIG. 25, as the output arm 196 of the wrist flexionassembly 22 is actuated, the hand assembly 24 is also caused to move.The output arm 196 of the wrist flexion assembly 22 may be actuatedpivotally about wrist flexion pivot axle 208, as shown in FIG. 27,moving the hand interface 198 to the left or right, and thus pivotingthe hand assembly 24 in relation to the input support structure 192.

Referring back to FIG. 1, the wrist flexion assembly 22 is attached tothe wrist rotator 20 via wrist flexion assembly interface 172, shown inFIG. 23. Referring to FIGS. 23 and 24, when actuated, the wrist flexionassembly interface 172 is rotated about wrist shaft 188 in relation to10 the wrist outer bearing carrier 164. Therefore, the wrist flexionassembly 22, and attached hand assembly 24 are also caused to rotate inreference to the wrist outer bearing carrier 164 by actuation of thewrist rotator 20. Therefore, the wrist rotator 20 allows the prostheticarm apparatus 10 to move in rotation similar to a human wrist joint.

Referring back to FIG. 1, the wrist rotator 20 is attached to the elbowflexion assembly 18 via the wrist interface 130, shown in FIG. 18.Referring to FIG. 20, when the elbow flexion assembly 18 is actuated,the radial mount 122 is rotated about the axis of motor rotor 134. Thewrist rotator 20, wrist flexion assembly 22, and hand assembly 24 arethus also caused to rotate about the axis of motor rotor 134 becausethey are attached at the wrist interface to the radial mount 122.Therefore, the elbow flexion joint 18 allows the prosthetic armapparatus 10 to move similar to flexion extension of a human elbowjoint.

Referring back to FIG. 1, the elbow flexion assembly 18 is attached tothe humeral rotator 16 via the humeral mount 96, shown in FIG. 16.Referring to FIG. 16, actuation of the humeral rotator 16 causes thehumeral mount 96 to rotate in relation to the outer bearing carrier 90of the humeral rotator 16. Since the elbow flexion assembly 18, wristrotator 20, wrist flexion 25 assembly 22, and hand assembly 24 areattached to the humeral mount 96, they are also caused to rotate inrelation to the outer bearing carrier 90. This allows the prosthetic armapparatus 10 to rotate to perform an arm wrestling motion.

Referring back to FIG. 1, the humeral rotator 16 is attached to theshoulder flexion assembly 14 through the humeral interface 46, shown inFIG. 9. Referring to FIG. 9, actuation of the shoulder flexion assembly14 causes the main shoulder housing 42 to pivot about the center of theabductor interface 44. Since the humeral rotator 16, elbow flexionassembly 18, wrist rotator 20, wrist flexion assembly 22, and handassembly 24 are attached to the main housing 42, they are also caused torotate in relation to the abductor interface 44. Therefore, the shoulderflexion assembly 14 allows the prosthetic arm apparatus 10 to move alongthe torso simulating running motion.

Referring to FIG. 1, the shoulder flexion joint 14 is attached to theshoulder abductor 12 through the shoulder flexion assembly mount 30,shown in FIG. 5. Referring to FIG. 5, the shoulder abductor 12 isattached to a harness that is worn by the user via harness mount 26.When the shoulder abductor 12 is actuated in a positive direction, theshoulder flexion assembly mount 30 pivots away from the harness mount26, and the user. Similarly, by actuating the shoulder abductor in anegative direction, the shoulder flexion assembly mount 30 is pivotedtoward the harness mount 26 and the user. Since the shoulder flexionassembly 14, humeral rotator 16, elbow flexion assembly 18, wristrotator 20, wrist flexion assembly 22, and hand assembly 24 are attachedto shoulder abductor 12 at the flexion assembly mount 30, they are alsocaused to pivot with the shoulder flexion assembly mount 30.

One characteristic of the prosthetic arm apparatus described herein isthat it provides the user with substantially the same movementcapabilities and degrees of freedom of a human arm, including twodegrees of freedom in shoulder functionality. Additionally, themodularity of each segment of the prosthetic arm apparatus 10 provides asignificant advantage over conventional prosthetic devices. Inparticular, since each segment of the plurality of segments operatesindependently of each other segment of the plurality of segments, fewersegments may be used for less severe amputees. For example, atranshumeral amputee may have full shoulder functionality in theresiduum, in which case the shoulder abductor 12 and shoulder flexionassembly 14 segments would be omitted from the prosthetic arm apparatus10. The resulting prosthetic arm apparatus 10 would include the humeralrotator 16, the elbow flexion assembly 18, the wrist rotator 20, thewrist flexion assembly 22, and the hand assembly 24, wherein the humeralrotator 16 would be attached to the prosthetic harness. In some cases,the residuum of the transhumeral amputee may even have humeral rotation,in which case the prosthetic arm apparatus 10 may be further simplifiedto include only the elbow flexion assembly 18, the wrist rotator 20, thewrist flexion assembly 22 and the hand assembly 24, with the elbowflexion assembly 22 being attached to the prosthetic support apparatus.Similarly, for a transradial amputee, the prosthetic arm apparatus 10may include only the wrist rotator 20, wrist flexion assembly 22 and thehand assembly 24, with the wrist rotator 20 being attached to theprosthetic support apparatus. Additionally, in some embodiments, theprosthetic arm apparatus 10 may be further simplified to include onlythe wrist flexion assembly 22 and the hand assembly 24 when thetransradial amputee has wrist rotation in their residuum. In theseembodiments, the wrist flexion assembly 22 may be attached to theprosthetic support apparatus. Thus, the modularity of each segment ofthe prosthetic arm apparatus 10 advantageously allows for customizationof different prosthetic arm configurations for various users based onthe differing degrees of amputation of each user.

A further advantage of the present invention is the use ofnon-backdriving clutches to preclude movement of the segments due toforces exerted on the prosthetic arm apparatus 10 when not in motion.These non-backdriving clutches may be particularly beneficial when thesegments of the prosthetic arm apparatus 10 have different strengthcapacities so that the clutches for specific segments of the prostheticarm apparatus 10 may lock those segments while other stronger segmentsare actuated to lift heavy objects. For instance, the non-backdrivingclutch in the shoulder flexion assembly 14 may be used to lock outshoulder movement while the elbow flexion assembly 18 is actuated tolift a heavy object. The non-backdriving clutches may alsoadvantageously conserve power since the non-backdriving clutches preventmotion without using power. Thus, the power to specific segments of theprosthetic arm apparatus 10 may be shut off, on a segment-by-segmentbasis, when not in use, since the non-backdriving clutches in thosesegments are locking out motion. Additionally, the non-backdrivingclutches may also save power by allowing power to the entire prostheticarm apparatus 10 to turned off whenever the arm is not in motion whilemaintaining the prosthetic arm apparatus 10 in a locked position.

An additional characteristic of the apparatus is that the hand assemblyincludes independently moving fingers and is capable of completing finetasks such as pinching, grasping non-uniform objects, and lifting smallobjects off flat surfaces. Also, the tactile feedback sensor providesthe user with feedback, during use of the prosthetic arm apparatus, suchas the force of a grip. The apparatus also includes a cosmesis coveringon the finger structures, which will be discussed in greater detailbelow, providing, amongst other things, grip for grasping objects. Therigid fingernail 304, shown in FIG. 34, which may be included on any ofthe finger structures, provides a backstop for the finger cover toenhance gripping capability. The rigid fingernail 304 also enhancesgripping capability by anchoring the finger cover to the finger andallows the user to lift small objects from a surface with the prostheticarm apparatus 10.

Referring to FIG. 42A, wherein like numerals represent like elements, insome embodiments, the shoulder abductor 12 and the shoulder flexionassembly 14 shown in FIG. 2, may be integrated as a single shoulder unit1416, providing both degrees of freedom provided by the shoulderabductor 12 and shoulder flexion assembly 14 of FIG. 2. The singleshoulder unit 1416 includes a shoulder housing 1418 pivotally connectedto the harness mount 1026, which allows the shoulder unit 1416 to beconnected to a prosthetic harness (not shown) as discussed above. Insome embodiments, the shoulder housing 1418 has a smooth outer surface1419 to shape the shoulder unit 1416 to be similar to a human arm. Theshoulder housing 1418 is divided into a flexor portion 1420 and anabductor portion 1422, which are movable relative to one another. Theflexor portion 1420 of the shoulder housing 1418 includes the humeralinterface 1046 for connecting the humeral rotator 16, shown in FIGS. 1and 2, to the shoulder unit 1416. The abductor portion 1422 of theshoulder housing 1418 is pivotally connected to the harness mount 1026,which allows the shoulder unit 1416 to interface with a prostheticharness (not shown) as discussed above.

Referring to FIGS. 42B and 42C, within the housing 1418 is a shoulderflexion drive 1424 for causing flexion motion of the flexor portion 1420about a shoulder flexion axis 1426 and an abduction drive 1428 forcausing abduction motion of the shoulder housing 1418 about an abductionaxis 1430. Additionally, the housing also defines an electronicscompartment 1432 for housing control systems and circuits for theintegrated shoulder unit 1416.

The shoulder flexion drive 1424, in one embodiment, includes a shoulderflexion motor 1434 having motor shaft 1058 for driving the shoulderflexion motor pulley 1056. The shoulder flexion motor pulley 1056 drivesthe shoulder flexion belt 1060, which, in turn, drives the shoulderflexion belt-driven pulley 1062. The shoulder flexion belt-driven pulley1062 drives the wave generator 1064 of a shoulder flexion harmonic drivegearing system 1436, the output of which is fixedly interfaced with theabductor portion 1422. Thus, as power is transmitted through theshoulder flexion drive 1424 from the shoulder flexion motor 1434 to theoutput of the harmonic drive gearing system 1436, the flexor portion1420 rotates relative to the abductor portion 1422 about the shoulderflexion axis 1426. In some embodiments, the motor shaft 1058 and thewave generator 1064 are both hollow shafts to allow passage of anabductor motor shaft 1438 and an abductor screw shaft 1440,respectively, as will be discussed in greater detail below.

In the exemplary embodiment, the abduction drive 1428 includes theabductor motor 1036 for driving the abductor motor shaft 1438. Theabductor motor shaft 1438 is configured to drive the abductor belt 1038about its distal end. The abductor belt 1038, in turn, drives theabductor screw shaft 1440, which has an abductor nut 1442 threadedlycoupled thereto. The abductor nut 1442 is connected to the harness mount1026 through a linkage 1444, which is, in some embodiments, a four barlinkage. As power is transmitted through the abductor drive 1426 fromthe abductor motor 1036 to the abductor screw shaft 1440, the screwshaft 1440 rotates. The rotation of the screw shaft 1440 causes theabductor nut 1442 to displace axially along the screw shaft 1440, whichcauses pivotal motion of the shoulder housing 1418 through the linkage1444 about the abduction axis 1430.

Referring to FIG. 42A, the relative movement between the flexor portion1420 and the abductor portion 1422 provides the shoulder unit 1416 witha first degree of freedom similar to that of the shoulder flexion joint14 of FIG. 2. The abductor portion 1422 of the shoulder housing 1418 ispivotally connected to the harness mount 1026 at the abductor joint1034, providing the shoulder unit with the second degree of freedom byallowing the shoulder housing 1418 to pivot relative to the harnessmount 1026 in a similar manner to that discussed above in connectionwith the shoulder abductor 12 of FIG. 2. Referring to FIGS. 42B and 42C,the integrated shoulder unit 1416 locates the shoulder flexion axis 1426and the abduction axis 1430 relatively close to one another as comparedto separate shoulder flexion and shoulder abduction assemblies, whichprovides for more intuitive motion that more closely simulates themovement of a human shoulder.

The shoulder flexion drive 1424 and the abduction drive 1428 discussedabove include coaxial motors and coaxial shafts to minimize the size ofthe single shoulder unit 1416 and to reduce the weight thereof. Thus,these exemplary single shoulder unit 1416 is beneficial because itsweight relative to the separate shoulder abductor 12 and shoulderflexion assembly 14, shown in FIG. 2. Additionally, the single shoulderunit 1416 provides more narrow housing 1418, which allows a more naturalanatomical position of the shoulder for a broader range of users and mayreduce bumping with the user's residuum during use. This embodiment hasan additional benefit of decreasing the weight of the prosthetic.Additionally, as seen in FIGS. 42B and 42C, both the abduction motor1036 and the shoulder flexion motor 1434 may be located in the vicinityof the electronics compartment 1432, so the electronics for both theshoulder flexion drive 1424 and the abduction drive 1428 may be locatedin the same place, which eliminates any need to route wiring through theshoulder unit 1416. This is advantageous since running wires acrossjoints is a failure mode in which the wires may crimp and break whenmoved. Thus, the shoulder unit 1416 eliminates this failure mode byeliminating wires running across the joints that could cause failure ofthe prosthetic arm 1010.

Although the shoulder flexion drive 1424 and the abduction drive 1428have been shown in an exemplary configuration, it should be understoodby those skilled in the art that other drive configurations may also beused to drive the single shoulder unit 1416 about the shoulder flexionaxis 1426 and the abduction axis 1430. For instance, referring to FIG.43, the shoulder flexion motor 2434 and the abduction motor 2036 of thesingle shoulder unit 2416 do not need to be coaxial and they may stilleach be located within the housing 2418 in the vicinity of theelectronics compartment 2432. Additionally, rather than driving thelinkage 1444, shown in FIG. 42B, the worm drive 2041 may insteadthreadably engage an abduction gear 2446 coupled to the harness mount2026 to generate pivotal movement about the abduction axis 2430.

Additionally, referring now to FIG. 44, in various embodiments, theintegrated shoulder unit 3416 may shift the abduction output to changethe location of the harness mount (not shown) to improve mountinglocation and/or to allow for ninety degrees (90°) of abduction about theabduction axis 3430 without bumping with the residuum (not shown). Forexample, the location of the abduction output may be changed byextending the abduction drive 3428 with one or more additional shafts,gears, and/or belts.

Referring to FIG. 45, the flexion assembly mount 4030 may also beshifted away from the harness mount 4026 in the non-integrated shoulderabductor 4012. Referring to FIG. 46, the flexion assembly mount 4030 mayalso include an accommodating slot 4031 adapted to accommodate portionsof the abductor joint 4034, shown in FIG. 45. Referring back to FIG. 45,the shifted flexion assembly mount 4030 allows the user to orient theshoulder abductor 4012 on the prosthetic support apparatus (not shown)in different orientations while still allowing a range of motion of theshoulder abductor 4012 of at least approximately ninety degrees (90°).This may be particularly advantageous since the mounting orientation ofthe shoulder abductor 4012 may vary from user to user, which may limitthe range of abduction motion with the non-shifted flexion assemblymount 30, shown in FIG. 6. Additionally, in some embodiments, theshifted flexion assembly mount 4030 may house a flex sensor plunger fordetecting flexion motion of the shoulder flexion assembly 4014.

Referring to FIG. 47A, in some embodiments of the present invention, theprosthetic arm apparatus 10, shown in FIG. 1, may include a shoulderfree swing system 5770 including a housing 5772 having a harness mount5026 fixedly secured thereto for attaching to a prosthetic harness. Theshoulder free swing system 5770 also includes an arm interface 5774rotatably secured within the housing 5772 inside a bearing 5776. The arminterface 5774 includes mounting holes 5778 for connecting the shoulderfree swing system 5770 to the shoulder unit 1416, shown in FIG. 42B,through the abduction axis 1430 and the linkage 1444, each shown in FIG.42B.

Referring to FIGS. 47B and 47C, within the housing 5772, the arminterface 5774 includes a substantially circular portion 5779 that, atits outer circumference, engages the bearing 5776. The substantiallycircular portion 5779 includes a plurality of locking ramps 5780 formedtherein about its inner circumference and may also include one or moremagnets 5781 disposed at the outer portion of the locking ramps 5780.Within the substantially circular portion 5779, the shoulder free swingsystem 5770 includes a plurality of locking plates 5782, each of whichhas a rotation pin 5783 secured to the housing 5772 about which thelocking plate 5782 may pivot. The locking plates 5782 include lockingteeth 5784 configured to engage the locking ramps 5780 of the arminterface 5774. The locking plates 5782 also include cam followers 5785for engaging a cam plate 5786 through cam paths 5788. The cam plate 5786is connected to a handle 5790 through an actuation plate 5792, shown inFIG. 47A. The handle 5790 extends out of the housing 5772, therebyallowing for user actuation thereof.

In operation, when the locking teeth 5784 of the locking plates 5792 aredisengaged from the locking ramps 5780 of the arm interface 5774, asshown in FIG. 47B, the arm interface 5774 is able to freely rotate withrespect to the harness mount 5026, with its substantially circularportion 5779 rotating within the bearing 5776. However, when the usermoves the handle 5790 from the position shown in FIG. 47B to theposition shown in FIG. 47C, the actuation plate 5792 rotates, which inturn rotates the cam plate 5786 and causes the locking plates 5782 torotate until the locking teeth 5784 engage the locking ramps 5780 of thearm interface 5774. The one or more magnets 5781 may advantageously aidin the engagement by drawing the locking teeth 5784 into the lockingramps 5780 and by eliminating backlash. Once the locking teeth 5784 areengaged in the locking ramps 5780, the arm interface 5774 is no longerable to freely move with respect to the harness mount 5026, unless thehandle 5790 is returned to the position shown in FIG. 47B. Thus, whenthe locking teeth 5784 are engaged, the user may operate the prostheticarm apparatus 10, shown in FIG. 1, in substantially the same manner asdiscussed above.

The slopes of the locking teeth 5784, the locking ramps 5780 and the campaths 5788 may advantageously be designed such that the locking teeth5784 will automatically become disengaged the from the locking ramps5780 if a torque being transmitted through the shoulder free swingsystem 5770 is exceeds a maximum release torque. For example, in someembodiments the locking teeth 5784 may disengage the locking ramps 5780if the torque being transmitted through the free swing system 5770exceeds fifty Newton meters. Thus, the shoulder free swing system 5770advantageously prevents excessive loading from being transmitted throughthe prosthetic device without permanently damaging any components of theprosthetic arm apparatus 10, shown in FIG. 1.

Referring to FIG. 48A, another embodiment of a shoulder free swingsystem 6770 is shown. The shoulder free swing system 6770 includes ahousing 6772 having a harness mount 6026 fixedly secured thereto forattaching to a prosthetic harness. The shoulder free swing system 6770also includes an arm interface 6774 rotatably secured within the housing6772. The arm interface 6774 includes mounting holes 6778 for connectingthe shoulder free swing system 6770 to the shoulder unit 1416, shown inFIG. 42B, through the abduction axis 1430 and the linkage 1444, eachshown in FIG. 42B.

Referring to FIG. 48B, a portion 6794 of the arm interface 6774 isrotatably secured in the housing 6772 within bearing 6776. The portion6794 has a tapered surface 6796 at its inner circumference that contactsa corresponding tapered surface 6798 of a friction plate 6800, therebyforming a tapered frictional interface between the arm interface 6774and the friction plate 6800. Two or more breakaway locks 6802 are loadedbetween the arm interface 6774 and the friction plate 6800, eachbreakaway lock 6802 having a spring (not shown) that tends to separatethe friction plate 6800 from the arm interface 6774. The friction plate6800 includes ball bearings 6804 located within grooves 6806 at itscircumference that allow linear motion along an axis 6808, but resistrotation due to an applied torque. The breakaway locks 6802 and thegeometry of the tapered surfaces 6796 and 6798 are configured so thatthe friction plate 6800 and the portion 6794 of the arm interface 6774separate at a desired applied torque, for example, fifty Newton meters,thereby allowing the arm interface 6774 to slowly rotate while engagingthe friction plate 6800 at the tapered surface 6798 to lower theprosthetic arm apparatus 10, shown in FIG. 1, until it loses itspotential energy. To manually engage and/or disengage the free swingsystem 6770 The handle 6790 may be rotated to move a ramp 6810 linearlyinward or outward along axis 6808, thereby reengaging or disengaging,respectively, the breakaway locks 6802 and, therefore, the free swingsystem 6770.

Referring now to FIG. 49, another embodiment of the wrist rotator 1020is shown for providing improved electronic wiring capability to theprosthetic device. Although shown as the wrist rotator 1020, it shouldbe understood by those skilled in the art that a similar configurationmay be used for other rotating joints, such as the humeral rotator 16,shown in FIG. 1. In this embodiment of the wrist rotator 1020, the wristrotator motor 1448, including the wrist rotator motor armature 1174 anda driven portion 1450 of the wrist rotator motor rotor 1176 having wristrotator magnets 1178 disposed thereon, and the wrist harmonic drivegearing system 1452, including the wrist rotator harmonic drive gearingsystem wave generator 1180, the wrist rotator harmonic drive gearingsystem flexspline 1182 and the wrist rotator harmonic drive gearingsystem circular spline 1184, are separated into coaxial side-by-sideunits with the wrist rotator motor 1448 being proximate to the elbowinterface 1170 and the harmonic drive gearing system 1452 beingproximate to the wrist flexion assembly interface 1172. By arranging thewrist rotator motor 1448 and the wrist harmonic drive gearing system1452 in the side-by-side configuration, the electronics channel 1190passing through the center of the wrist rotator rotor 1176 may be formedlarge enough to allow electronic wiring to be run internally through thecenter of the wrist rotator 1020. Referring to FIGS. 50 and 51, thewiring through the prosthetic arm 10, shown in FIG. 1, in someembodiments, may run through one or more extension springs 1454, inparticular around the flexion joints, such as the elbow flexion assembly18 and the wrist flexion assembly 22, shown in FIG. 1, where internalwiring is difficult or impractical.

Routing the wiring through the center of the wrist rotator 1020eliminates the need for external wiring, thereby minimizing any flexingmovement experienced by the wiring, which can cause wire pinching,abrasions and failure. The internal wiring also eliminates thepossibility that external wiring will become caught on something andbreak. Routing the wiring through the one or more extension springs 1454where internal wiring is not practical, possible or desired allows forcontrolled loading of the external wiring and protects the wiring frompinching to reduce wire failure.

Referring to FIG. 52, in another embodiment of the wrist flexionassembly 1022, the output arm 1196 is able to move in flexion relativeto the input support structure 1194 about a flexion axis 1456 and tomove in ulnar-radial deviation relative to the input support structure1194 about a deviation axis 1458. Thus, when the hand assembly 24, shownin FIG. 1, is attached to the output arm 1196 of the wrist flexionassembly 1022, the hand assembly 24, shown in FIG. 1, is able to move inboth flexion and ulnar-radial deviation.

Referring to FIG. 53, the wrist flexion assembly 1022 includes two wristmotors 1202, for controlling the flexion and ulnar-radial deviation ofthe output arm 1196, shown in FIG. 52. Each wrist motor 1202 drives aninput geartrain 1460, which, in turn, drives a wrist worm gear 1462.Each worm gear 1462 drives an input gear 1464 of a wrist differential1466. The wrist differential 1466 includes a first bevel gears 1468 anda second bevel gear 1470 that are rotatable about the flexion axis 1456.The first bevel gear 1468 and the second bevel gear 1470 may be drivenby one of the input gears 1464. The wrist differential 1466 alsoincludes a differential body 1472 rotatably attached about the flexionaxis 1456 between the first and second bevel gears 1468 and 1470. Anulnar-radial axle 1474 extends from one side of the differential body1472 along the ulnar-radial axis 1458 and a third bevel gear 1476extends from the differential body 1472 on the opposite side thereof.The third bevel gear 1476 is rotatable about the ulnar-radial axis 1458and meshes with and is driven by the first bevel gear 1468 and thesecond bevel gear 1470.

In operation, the user is able to actuate wrist flexion, wristulnar-radial deviation and combinations thereof by actuating the motors1202 in various ways. For example, referring to FIG. 54, if the motors1202 are driven at the same speed in opposite directions, i.e. one isdriven clockwise and the other counterclockwise, the output arm 1196,shown in FIG. 52 will move in flexion in one direction about the flexionaxis 1456. If the direction of each motor is reversed, i.e. fromspinning clockwise to counterclockwise and vice versa, the output arm1196, shown in FIG. 52, will flex in the opposite direction. Similarly,referring to FIG. 55, if the motors 1202 are driven at the same speed inthe same direction, i.e. both are driven clockwise, the output arm 1196,shown in FIG. 52, will move in ulnar-radial deviation in one directionabout the deviation axis 1458. If the direction of each motor isreversed, i.e. from spinning clockwise to counterclockwise, the outputarm 1196, shown in FIG. 52, will move in ulnar-radial deviation in theopposite direction about the deviation axis 1458. In addition to varyingthe direction of rotation of the motors 1202, varying the speed of onemotor 1202 relative to the other will result in a combination of flexionand ulnar-radial deviation. Accordingly, in this embodiment, wristflexion and ulnar-radial deviation may both be controlled simply byvarying the direction and speed of the motors 1202.

Although the wrist flexion assembly 1022 is described as having adifferential drive 1466 for imparting wrist flexion and wristulnar-radial deviation movement to the output arm 1196, it should beunderstood by those skilled in the art that other drives may be used toachieve similar capabilities. For instance, referring to FIG. 56, thewrist flexion assembly 2022 may include a separate wrist flexiongeartrain 2478 for imparting flexion motion to the output arm 2196 aboutthe flexion axis 2456 and a separate ulnar-radial geartrain 2480 forimparting ulnar-radial deviation to the output arm 2196 about thedeviation axis 2458.

Referring to FIG. 76, in another embodiment of the present invention, awrist flexion assembly 4022 is provided for imparting a combination ofboth flexion about the flexion axis 4456 and ulnar-radial deviationabout the deviation axis 4458 to the hand assembly 4024 in a singlemovement. The wrist flexion assembly 4022 includes the input supportstructure 4194 adapted to be connected to the wrist rotator 20, shown inFIG. 1, in the same manner as discussed above. The wrist supportstructure 4194 includes a hand interface 4626 proximate to the handassembly 4024 for attaching the hand assembly 4024 to the wrist supportstructure 4194. The wrist support structure 4194 houses a wrist motor202, shown in FIG. 26, which drives the wrist pivot axle 4208 in rotarymotion about the wrist flexion axis 4456 through an appropriate geartrain (not shown). The wrist pivot axle includes flattened end portions4628 at each end thereof, extending outwardly from the wrist supportstructure 4194 and into the hand interface 4626. Each flattened endportion 4628 has two substantially parallel planar surface 4630extending parallel to the wrist flexion axis 4456. The hand interface4626 includes a first cam bearing 4632 fixedly secured to the wristsupport structure 4194 about the flattened end portion 4628 of the wristpivot axle 4208 proximate to the thumb structure 4220 of the handassembly 4024. The hand interface also includes a second cam bearing4634 fixedly secured to the wrist support structure 4194 about theflattened end portion 4628 of the wrist pivot axle 4208 proximate to thepinky finger 4230 of the hand assembly 4024. Referring to FIG. 77, thefirst cam bearing 4632 includes a first cam profile 4636 formed therein.Referring to FIG. 78, the second cam bearing 4634 includes a second camprofile 4638 formed therein. Referring back to FIG. 76, the handinterface 4626 also includes first and second slider blocks 4640coupling the hand assembly 4024 to the wrist flexion assembly 4022. Thefirst and second slider blocks 4640 each have a proximate end 4642 atthe hand interface 4626 and a distal end 4644 near the hand assembly4024. Each of the first and second slider blocks 4640 has a slot 4646formed therein that slidably receives one of the flattened end portions4628 of the wrist pivot axle 4208. The first and second slider blocks4640 include cam followers 4648 at their proximate ends 4642 that arereceived within the first cam profile 4636 of the first cam bearing 4632and the second cam profile 4638, shown in FIG. 78, of the second cambearing 4634. The first and second slider blocks 4640 are pivotallycoupled to the hand assembly 4024 at their distal ends 4644 about pivotaxes 4650.

In this embodiment, the hand assembly 4024 may be angled away from theflexion axis 4456 about a wrist rotation axis 4652 to reduce the motionthat the first cam profile 4636 and the second cam profile 4638 need toproduce to achieve the desired combined flexion and ulnar-radialdeviation movement of the hand assembly 4024. In some embodiments, thehand assembly 4024 is angled approximately thirty degrees clockwise (30°clockwise) assuming left hand user perspective from the flexion axis4456.

Referring to FIGS. 79A-79C, in operation, the wrist motor 202, shown inFIG. 26, drives the wrist pivot axle 4208 in rotation movement about theflexion axis 4456, which provides the hand assembly 4024 with flexionmovement. Additionally, the sliding engagement between the flattened endportions 4628 of the wrist pivot axle 4208 and the first and secondslider blocks 4640 causes the first and second slider blocks 4640 topivot about the flexion axis 4456 as the wrist pivot axle 4208 rotates.As the first and second slider blocks 4640 pivot, the cam followers4648, shown in FIG. 76, follow the first cam profile 4636, shown in FIG.77, and the second cam profile 4638, shown in FIG. 78, which causes thefirst and second slider blocks 4640 to slide relative to the wrist pivotaxle 4208. This sliding motion of each of the first and second sliderblocks 4640 causes the hand assembly 4024 to pivot about the pivot axes4650, shown in FIG. 76, which results in the ulnar-radial deviationmovement of the hand assembly 4024. Thus, as the wrist motor drives thewrist pivot axle 4208, the hand assembly 4024 moves from a firstposition 4654, shown in FIG. 79A, in which the hand is fully flexed anddeviated in the ulnar direction, to a second position 4656, shown inFIG. 79B, which is a neutral position with respect to flexion movementbut includes some degree of ulnar deviation. Then, the hand assembly4024 continues to move until it reaches a third position 4658, shown inFIG. 79C, in which the hand assembly 4024 is fully extended about theflexion axis 4456 and is also fully deviated in the radial direction.

Referring to FIG. 80, the first cam profile 4636, shown in FIG. 77, andthe second cam profile 4638, shown in FIG. 78, provide for movement ofthe hand assembly 4024, shown in FIG. 76, along a constrainedflexion-deviation movement path 4660 that includes components of bothflexion motion and ulnar-radial deviation motion. The constrainedflexion-deviation movement path 4660 is advantageous because the useronly needs to think about controlling a single degree of freedom, unlikethe embodiments discussed above that provide independent wrist flexionmovement and ulnar-deviation movement. Additionally, the constrainedflexion-deviation movement path 4660 is beneficial because it providesfor full flexion movement and also provides for nearly full ulnardeviation without requiring full wrist flexion. Thus, functionality isparticularly beneficial when users use the prosthetic arm apparatus 10,shown in FIG. 1, to pick up an object (not shown) from overhead. Theconstrained flexion-deviation movement path 4660 also advantageouslyallows for approximately twenty-four degrees (24°) of flexion movementwithout significant ulnar deviation, which allows the user to move anobject, such as a spoon, in flexion motion without spilling itscontents. This range of flexion movement with minimal ulnar deviationprovided by the constrained flexion-deviation movement path 4660 mayalso be beneficial to compensate for offset in situations where theprosthetic arm apparatus 10, shown in FIG. 1, is mounted at an offset,for example, to avoid the user's residuum. Additionally, since the handassembly 4024, shown in FIG. 76, is angled in the neutral secondposition 4656, shown in FIG. 79B, pinching of the thumb structure 4220,shown in FIG. 76, and index finger structure 4222, shown in FIG. 76, aremore in line with the wrist rotation axis 4652, which makes varioustasks easier for the user, such as turning a door knob, turning a key orthe like. Thus, the constrained flexion-deviation movement path 4660, orother similar paths, provided by the wrist flexion assembly 4022, shownin FIG. 76, provides a variety of advantages over conventionalprosthetic devices.

Additionally, in some embodiments, the flexion axis 4456, shown in FIG.76, may be shifted from its neutral position to provide variousbenefits. For example, the flexion axis 4456, shown in FIG. 76, isshifted approximately thirty degrees (30°) from its neutral position.This shift provides a prosthetic hand attached to the wrist flexionassembly 4022, shown in FIG. 76, with a more natural appearance and mayaid in positioning the hand for various tasks, such as turning a doorknob, turning a key or the like.

Although described in terms of constrained flexion-deviation movementpath 4660, shown in FIG. 80, it should be understood by those skilled inthe art that the first cam profile 4636, shown in FIG. 77, and thesecond cam profile, shown in FIG. 78, may be formed in variousconfigurations to achieve a variety of different constrained movementpaths. Additionally, although the constrained flexion-deviation movementpath 4660 has been described in connection with the wrist flexionassembly 4022, the constrained flexion-deviation movement path 4660 mayalso be commanded using the flexion assembly 1022, shown in FIG. 52, byprogramming the prosthetic controller to actuate the motors 1202, shownin FIG. 53, to move the prosthetic hand assembly 24 along the sameconstrained flexion-deviation path 4660.

Referring to FIG. 81, in some embodiments, a compound motion assembly5662 may be provided to impart two-axis motion to the various segmentsdiscussed herein. The compound motion assembly 5662 includes an inputmember 5664, an output member 5666 and an intermediate member 5668. Theinput member 5664 is movably coupled to the intermediate member 5668through a first joint 5670 and the output member 5666 is movably coupledto the intermediate member 5668 through a second joint 5672 such thatthe first joint 5670 and the second joint 5672 are arranged in seriesbetween the input member 5664 and the output member 5666 with theintermediate member arranged therebetween.

The input member 5664 includes an input interface 5674 at one endthereof, two support posts 5676 extending outwardly from the inputinterface to the first joint 5670 and a path member 5678 secured to thesupport posts 5676 at the first joint 5670. The input interface 5674 hasbolt holes 5680 or similar connection means to allow the input member5664 to be secured to an adjacent segment of the prosthetic device 10,shown in FIG. 1, at the input interface 5674. The support posts 5676 arespaced apart from one another at a sufficient distance to accommodatethe intermediate member 5668 therebetween, as will be discussed ingreater detail below. The path member 5678 forms an arch extending overthe intermediate member 5668 and connecting one of the support posts5676 to the other support post 5676.

Referring to FIGS. 82 and 83, the path member 5678 includes an outersurface 5677 and an inner surface 5679 that are both substantiallyspherically shaped to ensure clearance between the path member 5678 andthe output member 5666 and the path member 5678 and the intermediatemember 5668, respectively. The path member 5678 also includes a baseportion 5682 at each end thereof for interfacing with the support posts5676, shown in FIG. 81. Each base portion 5682 includes mounting holes5684 for fastening the path member 5678 to the support posts 5676, shownin FIG. 81. The path member 5678 has a fixed path profile 5686 formedtherethrough and extending along at least a portion of the arch of thepath member 5678 between the two base portions 5682. The fixed pathprofile 5686 has a curvature that is selected to define the compoundmotion of the output member 5666 relative to the input member 5664, aswill be discussed in greater detail below. The fixed path profile 5686may be asymmetrical, as shown, or may instead be symmetrical dependingupon the desired compound motion.

Referring back to FIG. 81, as discussed above, the path member 5678 ispreferably a separate element fixedly secured to the support posts 5676so that the path member 5678 may advantageously be removed and replacedas will be discussed below. However, those skilled in the art shouldunderstand that the path member 5678 may instead be integrally formed aspart of the input member 5664.

Referring to FIGS. 81 and 84, the intermediate member 5668 of thecompound motion assembly 5662 is pivotally coupled to the input member5664 at the first joint 5670, such that the intermediate member 5668pivots about a first axis 5688 of the first joint 5670. The intermediatemember is suspended between the support posts 5676 and between the inputinterface 5674 and the path member 5678 by the first joint 5670 toensure clearance as the intermediate member 5668 pivots. Theintermediate member 5668 is coupled to the output member 5666 at thesecond joint 5672 such that the output member is able to pivot about asecond axis 5690 defined by the second joint 5672. In some embodiments,the first joint 5670 and the second joint 5672 are arranged relative toone another such that the first axis 5688 and the second axis 5690 aresubstantially coplanar, while in other embodiments, the first axis 5688and the second axis 5690 may not be substantially coplanar. Theintermediate member 5668 may have a spherical shape at the end proximatethe path member 5678 to ensure clearance between the intermediate member5668 and the path member 5678.

Referring to FIGS. 85 and 86, in some embodiments, the intermediatemember 5668 may include a housing 5692 enclosing a drive arrangement5694 for actuating the compound motion assembly 5662. The drivearrangement 5694 includes a motor 5696 coupled to an output shaft 5698through a gear train, which may include one or more reduction gears5702, a strain wave gearing system having a circular spline 5704, a wavegenerator 5706, a wave generator bearing 5708 and a flex spline 5710 orany other similar gearing system for transmitting torque from the motor5696 to the output shaft 5698. The output shaft 5698 extends outwardlythrough both sides of the housing 5692 and is rotatable supportedtherein by bearings 5712. Each end of the output shaft 5698 is securedto the output member 5666 to form the second joint 5672, shown in FIG.85, with the second axis 5690 being the axis of rotation of the outputshaft 5698. Securing the output shaft 5698 at each end to the outputmember 5666 provides increased torque to the output member 5666 when thedrive arrangement 5694 is actuated. However, in some embodiments, theoutput member 5666 may only be secured to the output shaft 5698 at oneend thereof, thereby simplifying the drive arrangement 5694. In theseembodiments, the other end of the output shaft 5698 may support theoutput member 5666 rotatably thereon.

Referring to FIG. 85, power to the motor 5696 is preferably suppliedthrough a circuit board 5714 secured within housing 5692. The circuitboard 5714 may include a shaft position sensor 5716 disposed thereon formonitoring movement of the output shaft 5698. For instance, the shaftposition sensor 5716 may be an optical sensor having an infrared emitterand receiver that transmits infrared light at a reflective cam surface5718 fixed to the output shaft 5698 and receives the reflected lightsignal, thereby enabling position detection. The circuit board 5714 mayalso include a temperature sensor (not shown) for monitoring thetemperature of the motor 5696 to ensure safe operation. The circuitboard 5714 may be connected to an external controller (not shown) forsupplying power and control to the motor 5696 and for receiving andprocessing position signals from the shaft position sensor 5716 and thetemperature sensor (not shown). In some embodiments, a single cable (notshown) may be used to connect the circuit board 5714 to the controller(not shown). This single cable (not shown) may reduce cable flex as thecompound motion assembly 5662 actuates, thereby reducing cable failure,which may result in possible damage to the compound motion assembly 5662or any components connected thereto. Preferably, the controller (notshown) shorts the motor 5696 when the compound motion assembly 5662 isnot being actuated to prevent back-driving of the compound motionassembly 5662, which may also result in possible damage to the compoundmotion assembly 5662 or any components connected thereto.

Referring back to FIG. 81, the output member 5666 includes two outputarms 5720, each secured to one end of the output shaft 5698, shown inFIG. 85, and extending outwardly past the path member 5678 to an outputinterface 5722. The two output arms 5720 are connected by a followermember 5724 having an extension 5726 that is accommodated within thefixed path profile 5686 of the path member 5678. The extension 5726 maybe, for example, a cam bearing for slidably engaging the fixed pathprofile 5686, as will be discussed below. Preferably, the followermember 5724 is removably coupled to the output arms 5720 by bolts 5728or the like. The output interface 5722 includes bolt holes 5680 orsimilar connection means to allow the output member 5666 to be securedto an adjacent segment of the prosthetic device 10, shown in FIG. 1, atthe output interface 5722. For example, referring to FIG. 87, thecompound motion assembly 5662 may be implemented as a prosthetic wristhaving the hand assembly 24 mounted to the output interface 5722.Preferably, when implemented as a prosthetic wrist, the cosmesis 1566,shown in FIGS. 67 and 69, would also extend over the compound motionassembly 5662 to protect the moving components of the compound motionassembly 5662 from contamination due to dirt of the like.

Referring to FIGS. 88A-88F, in operation, as the motor 5696, shown inFIG. 85, is actuated, the output shaft 5698, shown in FIG. 85, turnscausing pivotal movement of the output member 5666 at the second joint5672 about the second axis 5690. As the output member 5666 pivots at thesecond joint 5672, the extension 5726 of the output member 5666 slideswithin the fixed path profile 5686. As the extension 5726 slides withinthe fixed path profile 5686, the curvature of the fixed path profile5686 moves the extension 5726 laterally causing pivotal movement of theintermediate member 5668 relative to the input member 5664 at the firstjoint 5670. This pivotal movement also results in pivotal movement ofthe output member 5666 about the first axis 5688 of the first joint 5670since the output member 5666 is attached to the intermediate member5668. Thus, the compound motion assembly 5662 provides compound motionof the output interface 5722 relative to the input interface 5674 aboutboth the first axis 5688 and the second axis 5690 using a single motor5696, shown in FIG. 85. Therefore, the compound motion assembly 5662requires only a single degree of freedom as a control input, whichreduces the cognitive burden on the user while still providing a complexoutput movement.

As discussed above, the fixed path profile 5686 has a curvature that isselected to define the compound motion of the output member 5666relative to the input member 5664. Referring to FIG. 89, the fixed pathprofile 5686, shown in FIG. 81, produces compound motion path 5730having pivotal movement about both the first axis 5688 and the secondaxis 5690. It should be understood by those skilled in the art that thefixed path profile 5686 may be changed to produce alternative motionpaths 5732, depending upon the desired movement of the output interface5722, shown in FIG. 81. Thus, when the compound motion assembly 5662,shown in FIG. 87, is used with a prosthetic hand 24, shown in FIG. 87,the fixed path profile 5686 may be formed to provide theflexion-deviation movement path 4660, shown in FIG. 80, having all ofthe advantages discussed above in connection therewith. Alternatively,the fixed path profile 5686 may instead be formed to provide the handassembly 24, shown in FIG. 87, with an alternative movement path 5732having another advantageous path of movement for different user needs.

Referring back to FIG. 81, as discussed above, the path member 5678 ispreferably removably attached to the support posts 5676. Thisadvantageously allows the path member 5678 to be easily removed from thecompound motion assembly 5662 and replaced if damaged or if analternative motion path 5732, shown in FIG. 89, is desired for theoutput interface 5722. Thus, the compound motion assembly 5662 mayadvantageously be reprogrammed for different uses or different users bythe swapping of a single part. Additionally, when implemented as aprosthetic wrist, as shown in FIG. 87, the compound motion assembly 5662may be switched from a right handed to left handed prosthetic wrist, andvice versa, by changing only the path member 5678 and the output arms5720, each of which is advantageously removably attached to the compoundmotion assembly for easy removal and installation.

Referring to FIG. 90, in some embodiments, the compound motion assembly5662 and any metal structure secured thereto, such as hand assembly 24,shown in FIG. 87, may be incorporated into a first antenna 5818 forcommunication between the arm control module (ACM) stack 5128 and anexternal device such as a control unit for the prosthetic arm apparatus10, shown in FIG. 1. The compound motion assembly 5662 forms a radiatingelement 5820 of the first antenna 5818 and a first printed circuitboard5822 of the ACM stack 5128 connected to the radiating element 5820provides the remainder of the antenna 5818.

Referring to FIG. 91, the compound motion assembly 5662 includes agrounding disc 5824 at the interface with the ACM stack 5128, shown inFIG. 90, that electrically isolates the radiating element 5820 from thefirst printed circuitboard 5822. A screw connection 5826 passes throughthe grounding disc 5824 to allow the printed circuitboard 5822 to besecured thereto with a screw (not shown). The screw connection 5826advantageously facilitates both a mechanical connection between theprinted circuitboard 5822 and the radiating element 5820 as well as anelectrical connection between the radiating element 5820 and the antennamatching network circuit on the printed circuitboard 5822.

Thus, referring to FIG. 92, the compound motion assembly 5662, as wellas any metal structure secured thereto, provides the radiating element5820 for the first antenna 5818, while the rest of the electricalcomponents of the first antenna 5818 may be housed on the printedcircuitboard 5822. In some embodiments, the impedance of the compoundmotion assembly 5662, as well any metal structure secured thereto, ismatched to that of the transceiver of the printed circuitboard 5822 toprovide for efficient energy transfer. By providing the entire compoundmotion assembly 5662, and any metal structure attached thereto, as theradiating element 5820, with its impedance matched to that of thetransceiver, the first antenna 5818 necessarily provides a better andmore robust antenna than substantially any antenna that could be housedwithin the wrist structure itself. Therefore, the first antenna 5818 mayadvantageously be implemented as the primary communication channel forthe prosthetic arm apparatus 10, shown in FIG. 1, transferring criticalcommands, such as commands relating to prosthetic movement, to and fromthe ACM stack 5128, shown in FIG. 90. Additionally, due to the size ofthe radiating element 5820, the signaling to and from the first antenna5818 is less susceptible to multi-path interference, which oftenpresents a significant problem for short-range communications withinbuildings due to signal reflections and the like.

Although multi-path interference is not a significant problem for thefirst antenna 5818 due to the size of the radiating element 5820, itmay, in some embodiments, be a problem for short-range communicationswithin buildings. In particular, typical short-range communicationfrequencies, for example, approximately 2.5 GHz, do not typically passthrough human torsos. Additionally, signal reflection within a buildingmay result in signals that are the same, except 180 degrees out ofphase, being received by an antenna, which causes the signals randomlyand periodically to completely cancel.

Accordingly, referring to FIGS. 93 and 94, a second antenna 5828 forovercoming the transmission issues associated with in-buildinginterference may be formed entirely on a second printed circuitboard5830 of the ACM stack 5128, shown in FIG. 90. The second antenna 5828includes a first chip antenna 5832 and a second chip antenna 5834mounted on the printed circuitboard 5830 at an angle of approximately 90degrees relative to one another. The first chip antenna 5832 and thesecond chip antenna 5834 are connected to a transceiver 5835, shown inFIG. 93, of the second antenna 5828 through a combiner 5836 thatpassively combines signals received by the first and second chipantennas 5832 and 5834 by taking only the stronger of the two signals.In some embodiments, the combiner 5836 may be a 90 degree phasecombiner, while in other embodiments the combiner may include some otherphase angle. Additionally, although the first and second chip antennas5832 and 5834 have been described as being offset approximately 90degrees relative to one another, one skilled in the art shouldunderstand that the first and second chip antennas 5832 and 5834 may beoffset at other angles to suit some other need while still achievingsubstantially the same benefit as that achieved with the 90 degreeoffset.

The offset angle between the first chip antenna 5832 and the second chipantenna 5834 advantageously allows the second antenna 5828 to mitigatemulti-path interference by capturing signals in different phase angles.Thus, the second antenna 5834 may advantageously provide the prostheticarm apparatus 10, shown in FIG. 1, with a secondary antenna for lesscritical signals where some interference is acceptable. For example, thesecond antenna 5828 may be used for calibration of the prosthetic armapparatus 10, shown in FIG. 1, via a personal computer or fordownloading data logs from the prosthetic arm apparatus 10, shown inFIG. 1, to the personal computer. Thus, while some embodiments of thepresent invention may implement only the first antenna 5818, shown inFIG. 90, or the second antenna 5828, other embodiments may implementboth the first and second antennas 5818 and 5828 to cooperate andprovide a more robust communication system.

Although described herein in the context of a prosthetic arm and/orprosthetic hand, it should be understood that the antennas describedherein may be used for communication in various other devices and arenot necessarily limited to use in a prosthetic arm/prosthetic hand.

Referring to FIG. 95, in some embodiments, compound motion assembly 6662may include a path member 6678 having the fixed path profile 6686 formedon each peripheral edge thereof. In this embodiment, the output member6666 includes two extensions 6726, each extension 6726 engaging one ofthe fixed path profiles 6686. This embodiment operates in substantiallythe same manner as the embodiments discussed above. However, thisembodiment may advantageously provide for a more compact compound motionassembly 6662.

Referring back to FIG. 81, although described in connection with thedetailed embodiments herein, it should be understood by those skilled inthe art that the compound motion assembly 5662 may advantageously beimplemented in various industrial and manufacturing environments, or thelike. Thus, the compound motion assembly may provide equipment and/ormachinery having complex compound motion paths 5730, shown in FIG. 89,controlled through simplified single degree of freedom inputs. In theseembodiments, the compound motion assembly 5662 may be scaled up or downin size to meet specific or desired requirements. Additionally, pathmembers 5678 may be swapped in and out to alter the compound motion path5730, shown in FIG. 89. The input interface 5674 may advantageously besecured to a floor, a table or similar workstation to provide a fixedframe of reference from which the output interface 5722 is actuated.Additionally, the output interface 5722 may advantageously be adapted toaccommodate various industrial or manufacturing tools thereon.

Still referring to FIG. 81, although the compound motion assembly 5662has been described as having a drive arrangement 5694, shown in FIG. 85,for actuating the compound motion assembly 5662, some embodiments of thepresent invention may not be powered, thereby simplifying the compoundmotion assembly 5662 by eliminating the drive arrangement 5694, shown inFIG. 85. For example, FIG. 96 shows an embodiment of a non-poweredcompound motion assembly 7662. The compound motion assembly 7662 may bemoved by hand and locked in a desired position through the use of abrake 7736, or the like. Additionally, some non-powered embodiments ofthe compound motion assembly 7662 may include a handle 7734 to providefor easier manual actuation of the compound motion assembly 7662.

Referring to FIG. 57A and FIG. 57B, in various embodiments, thenon-backdriving clutch 1070 may replace spacers of the input cage 1074with springs 1482 between the rollers 1072. The springs 1482 push therollers 1072 apart and into contact with both the race 1078 and theoutput polygon 1484, which may be an output hex 1076. Thus, when abackdriving torque (not shown) is applied to the output hex 1076 tofriction lock the rollers 1072 between the output hex 1076 and thebearing race 1078, the rollers 1072 are already contacting both the race1078 and the output hex 1076, thereby substantially eliminatingbacklash, i.e. a slight rotation of the output polygon 1076, when thebackdriving torque (not shown) is applied. Thus, the non-backdrivableclutch 1070 imparts a frictional lock, which additional backdrivingtorque (not shown) through the output hex 1076 will not overcome.Additionally, as discussed above in connection with FIG. 12, in variousembodiments, the non-backdriving clutch 1070 may unlock itself throughthe application of an input load through the input cage 1074. Variationsof this embodiment may include, but are not limited to, additional orfewer springs 1482, additional or fewer rollers 1072 or a differentlyshaped race 1078. For example, in various embodiments, the relativeposition of the output hex 1076 and the race 1078 may be shifted, i.e.,rather than the hollow, circular race 1078 with the output polygon 1484inside, in various embodiments, the clutch may include an outer hollowoutput polygon surrounding a circular race. Additionally, although shownas a coil spring, it should be understood by those skilled in the artthat the springs 1482 may be formed in various configurations and/orfrom a variety of metal or elastomeric materials to provide the forcefor separating the rollers 1072. In addition, the motor may be used toprovide additional inertia to reduce back driving of the system.

Referring to FIG. 57C, in some embodiments, the non-backdriving clutch1070 may be integrated in combination with a gearbox 1483 within asingle gearbox housing 1485. In this embodiment, the gearbox 1483 mayinclude an input 1487 for engaging and being driven by a motor (notshown) and an output 1489 that transmits torque from the motor (notshown) to the associated prosthetic joint or segment. For example, thecombination gearbox 1483 may be used for the two thumb drives 232, theindex drive 234 and the MRP drive 236, all shown in FIGS. 31-34, so thatthese drives may be assembled and disassembled as a single unit. Thisadvantageously allows sensitive clutch components to be isolated andprotected within a single housing 1485. Additionally, this allows thegearbox 1485 to built separately with the clutch 1070 and gearbox 1483therein and later assembled into the hand assembly 2024, shown in FIG.58A, as will be discussed below.

Referring to FIG. 58A, in some embodiments, the hand assembly 2024 mayinclude a plurality of self-contained subassemblies 2850 toadvantageously make assembly and/or disassembly of the hand assembly2024 easier. The self-contained subassemblies 2850 may be built inparallel and then quickly assembled into the full hand assembly 2024.The self-contained subassemblies 2850 may include, for example, thethumb drives 2232, the index drive 2236 and the MRP drive 2234, each ofwhich may include the integrated gearbox 1483 and clutch 1070, shown inFIG. 57C. The self-contained subassemblies 2850 may also include a firstMRP differential 2854 and a second MRP differential 2856 that may befully assembled as complete units and easily dropped into the handassembly 2024. The self-contained subassemblies 2850 may also includethe thumb assembly 2220, the thumb differential 2852 as well as each ofthe index finger 2222, middle finger 2226, ring finger 2228 and pinkyfinger 2230. This advantageously allows the four finger subassemblies tobe assembled as complete units and then assembled into the hand assembly2024 and retained therein using a single pin 2858. Thus, the pluralityof self-contained subassemblies 2850 may advantageously make assemblyand/or disassembly of the hand assembly 2024 easier and may reduce buildtime, since each self-contained subassembly 2850 may be completedseparately and simultaneously.

Still referring to FIG. 58A, in some embodiments, the index fingerstructure 2222 may include a base portion 2860 and a tip portion 2862,which are connected in a pivotal connection at a knuckle joint 2864. Thebase portion 2860 connects to the hand assembly 2024 through a pin hole2865 and includes a gear segment 2866 fixedly connected at its lowerend, which interfaces with the index drive 2234 to allow for controlledmovement of the base portion 2860 about the pin 2858.

Referring to FIG. 58B, within the index finger structure 2222 isdisposed a two-part linkage element 2868 that includes a non-circularpin hole 2870 at its lower end and pivot bar 2872 at its distal end. Thepivot bar 2872 connects to the tip portion 2862 at an offset locationfrom the knuckle joint 2864. The non-circular pin hole 2870 is disposedadjacent to the pin hole 2865 and allows the pin 2858 to passtherethough when the index finger structure 2222 is assembled to thehand assembly 2024, with a corresponding non-circular portion 2874,shown in FIG. 58A, of the pin 2858 engaging the non-circular pin hole2870. In operation, when actuated, the index drive 2234 drives the baseportion 2860 of the index finger structure 2222 through the gear segment2866. As the base portion 2860 moves, the two-part linkage 2868 remainsgrounded due to contact between the non-circular pin hole 2870 with thenon-circular portion 2874 of the pin 2858. This, in turn, causes thepivot bar 2872 to move the tip portion 2862 relative to the base portion2860, thereby achieving the movement of the index structure 2222 that iskinematically deterministic. Since the grounding of the two-part linkage2868 is achieved through insertion of the pin 2858, it mayadvantageously be accomplished at essentially any point during assemblyof the hand assembly 2024. Additionally, it also advantageously allowsthe index structure 2222 to be replaced without requiring disassembly ofthe hand assembly 2024 or a substantial part thereof.

Referring to FIG. 59, an embodiment for output load sensing through adrive 1486 having a worm gear 1488, such as the shoulder abduction drive3428 of FIG. 44, is shown. Including one or more worm gears 1488 in thedrive 1486 is beneficial because the worm gear 1488 may itself preventbackdriving. The worm gear 1488 may be arranged on a splined shaft 1490between a first spring 1492 and a second spring 1494. The splined shaftincludes a plurality of splines 1496 arranged axially around the surfaceof the splined shaft 1490 and a shaft input 1498 portion, which may berotated directly by a motor (not shown) or through a gear train or thelike. The worm gear 1494 is tubular and has an interior surface 1500designed to slidably interface with the splines 1496 of the splinedshaft 1490 such that the worm gear 1488 may slide axially along thesurface of the splined shaft 1490. The worm gear 1488 meshes with anoutput gear 1502 such that when the splined shaft 1490 is caused torotate through its shaft input portion 1498, the splined shaft 1490rotatably drives the worm gear 1488 through the splines 1496 which, inturn, drives the output gear 1502. When a load (not shown) is applied tothe drive through the output gear 1502, for example, if the user islifting an object, the load will generate a torque T at the output gear1502. Although the torque T will not cause the worm gear 1488 to rotate,the torque T may cause the worm gear 1488 to displace axially along thesplined shaft 1490 compressing one of the first spring 1492 or thesecond spring 1494, depending upon the direction of displacement. Thus,by designing the drive system 1486 with the first spring 1492 and thesecond spring 1494 of known spring constants, the compliance, i.e. thedisplacement of the worm gear 1488, may be measured to estimate theoutput load (not shown). This drive system 1486 for output load sensingis particularly beneficial since the compliance is still present oractive while the worm gear 1488 is not being rotated, but is insteadacting as a non-backdriving element.

The prevention of backdriving with the various systems discussed aboveis beneficial because it allows the user to maintain a position of theprosthetic arm 10, shown in FIG. 1, while under a load (not shown).However, referring to FIGS. 60A and 60B, in some embodiments, it may bedesirable to provide the various arm segments with break-away mechanisms2504 that will separate the drive output from the drive input to preventdamage to the drive system if the load becomes too large. The break-awaymechanism 2504 may include an input shaft 2506, an output shaft 2508 andtwo break-away spacers 2510 that are held in contact with the inputshaft 2506 and output shaft 2508 by a compression member 2512. The inputshaft 2506 and the output shaft 2508 each include a shaft body 2514 anda torque transmission tab 2516 extending axially outward from the shaftbody 2514 between the break-away spacers 2510. The compression elementmember 2512 surrounds the break-away spacers 2510 and sandwiches thetorque transmission tabs 2516 therebetween. The compression member 2512may be, for example, a snap ring, a round metal ring, an o-ring,multiple o-rings, a coil spring, or the like. The compression member2512 applies a preset compressive force to the breakaway spacers 2510.

In operation, the input shaft 2506 of the break-away mechanism 2504 isrotated by a motor (not shown) or the like to generate a desiredmovement of the prosthetic arm 10, shown in FIG. 1. Thus, the torquetransmission tab 2516 of the input shaft 2506 rotates and transmits therotation through the break-away spacers 2510 to the torque transmissiontab 2516 of the output shaft 2508 as long as the torque required tocause rotation of the torque transmission tab 2516 of the output shaft2508 is not large enough to overcome the preset compressive forceprovided by the compression member 2512. If the torque is large enoughto overcome the preset compressive force, the torque transmission tab2516 will push the break-away spacers 2510 apart and the torquetransmission tab 2516 will rotate between the break-away spacers 2510without transmitting torque therethrough. Thus, the break-away mechanism2504 may prevent torque above a preset level from being transmittedthrough the drive system, where it can damage the drive systemcomponents. Accordingly, the break-away mechanism 2504 may limit theamount of torque applied to sensitive parts of the various drive systemsof the prosthetic arm 10, shown in FIG. 1, and may, therefore, impart alonger lifespan on the prosthetic arm.

Referring to FIG. 61A, another embodiment of a breakaway mechanism 3504includes an input ring 3518 and an output ring 3520 connected by adetent ring 3522. The breakaway mechanism 3504 may be connected betweentwo prosthetic arm segments, for example, the input ring 3518 may beconnected to the shoulder unit 1416, shown in FIG. 42A, and the outputring 3520 may be connected to the humeral rotator 16, shown in FIG. 1.Referring to FIGS. 62B and 62B, in some embodiments, the input ring3518, output ring 3520 and the detent ring 3522 each includes analignment marker 3524 on its outer surface 3526 to indicate properpositioning of the breakaway mechanism 3504.

Referring to FIG. 61B, the output ring 3520 includes a central hub 3528having an outer surface 3529 with a plurality of spring fingers 3530radiating therefrom. Each spring finger 3530 has a first detent 3532 anda second detent 3534 along its length and a pin 3536 at its distal end3538. The input ring 3518 includes a plurality of detents 3540 aroundthe circumference of its inner surface 3542, within which the pins 3536of the spring fingers 3530 may engage, as will be discussed in greaterdetail below. The detent ring 3522 includes a plurality of detent pins3544 located partway between the inner surface 3542 of the input ring3518 and the outer surface 3529 of the output ring 3520. The detent pins3544 engage the first detents 3532 of the spring fingers 3530 duringnormal operation of the breakaway mechanism 3504, i.e. when torque isbeing transmitted through the breakaway mechanism 3504.

However, referring to FIG. 62A, if an overtorque situation occurs, thepins 3536 at the distal ends 3538 of the spring fingers 3530 will popout of the ring detents 3540 so that the torque will not be transmittedback to the input ring 3518. Additionally, referring to FIG. 62B, theovertorque situation will also cause the alignment markers 3524 to moveout of alignment. The user may then realign the alignment markers 3524to transmit torque through the breakaway mechanism 3504.

Referring to FIG. 63A, the user may also intentionally disengage thetorque transmission by moving the alignment marker 3524 on the detentring 3522 up to engage the breakaway mechanism 3504 in freeswing. Asseen in FIG. 63B, this configuration entirely disengages the springfingers 3530 from the input ring 3518, thereby allowing the output ring3520 to rotate freely without driving the upstream components throughthe input ring 3518. Thus, this embodiment of the breakaway mechanism3504 is advantageous because it also allows for the user to engagefreeswing of the prosthetic arm 10, shown in FIG. 1.

These break-away mechanisms discussed above are beneficial because theyprevent damage to the prosthetic arm apparatus 10 and increase usersafety under high loading situations. Additionally, the break-awaymechanisms are advantageous in that once the break-away mechanisms breakunder high loading, they may be reset by the user without the need tosee a prosthetic technician.

As discussed above, various embodiments of the prosthetic arm 10, shownin FIG. 1, include feedback mechanisms for compliance and positionsensing, such as potentiometer 48, shown in FIG. 10. Referring now toFIG. 64, in some embodiments, the prosthetic arm 10, shown in FIG. 1,may include other feedback mechanisms, for example, a magnetic positionsensor 1546. In these embodiments, at least one magnetic strip 1548 maybe attached about the circumference of an inner surface 1550 of arotatable drive component 1552. The magnetic strip 1548 includes aplurality of magnets 1554 of known length L1 arranged in series, eachhaving a north pole N and a south pole S. Thus, the magnetic strip 1548generates a magnetic field having a repeating pattern of alternatingnorth poles N and south poles S. The magnetic position sensor 1546 isarranged to detect this magnetic field generated by the magnetic strip1548. In operation, the rotatable drive component 1552 rotates, whichcauses the magnetic strip 1548 to rotate, thereby moving the portion ofthe magnetic strip 1548 being detected by the magnetic position sensor1546. The magnetic position sensor 1546 detects this change in themagnetic field as the magnetic strip 1548 rotates from each north pole Nto each south pole S and vice versa. Since the length L1 of each magnet1554 is known, the detected changes in the magnetic field between eachnorth pole N and/or each south pole S may be converted into the distanceof rotational movement of the rotatable drive component 1552. Thus, thechange in position of the rotatable drive component 1552 may bedetected. The magnetic position sensor 1546 is also advantageous becauseit does not contact the rotating drive component 1552 and, therefore,will not experience contact wear due to the rotation of the rotatabledrive component 1552.

Referring to FIG. 65, in some embodiments, two magnetic position sensors1546 may be used to detect the magnetic fields generated by the firstmagnetic strip 1548 and a second magnetic strip 1556 arranged next toeach other around the circumference of the inner surface 1550 of arotatable drive component 1552. A length L2 of each magnet 1558 of thesecond magnetic strip 1556 is, in some embodiments, different than thelength L1 of the magnets of the first magnetic strip 1548. Thisdifference in length allows for the magnetic position sensors 1546 tosense unique combinations of magnetic field values from the firstmagnetic strip 1548 and the second magnetic strip 1556 over thecircumference of the inner surface 1550. Each unique magnetic fieldvalue may correspond to a position of the drive component 1552 and,therefore, absolute position of the drive component 1552 may be detectedby the two magnetic position sensors 1546.

In practice, the hand assembly 24, shown in FIG. 1, and particularly,the fingers of the hand assembly 24, i.e. the thumb structure 220, indexfinger structure 222, middle finger 226, ring finger 228 and pinkyfinger 230, all shown in FIG. 3, come into contact with objectsfrequently and, therefore, may be susceptible to wear and damage. Thus,referring to FIG. 66, it may be desirable for the prosthetic handassembly 1024 to include removable fingers 1560. In this embodiment ofthe prosthetic hand assembly 1024, the removable fingers 1560 may beremoved to allow for easier replacement of damaged fingers 1560 andalso, to allow for easily customizable or tailored finger lengths fordifferent user.

Each removable finger 1560 is driven in substantially the same manner asthe fingers of the previously discussed embodiments. However, theremovable fingers 1560 pivot about a common finger shaft 1562, ratherthan the individual pivot axles discussed in connection with FIG. 33. Insome embodiments, end caps 1564 cover each end of the common fingershaft 1562 to prevent dirt or other contaminants from getting into thegear trains of the hand assembly 1024 and also to ensure that the commonfinger shaft 1562 does not become axially displaced unintentionally. Inoperation, either end cap 1564 may be removed from the hand assembly1024 and the common finger shaft 1562 may be extracted to free theremovable fingers 1560. Each finger 1560 may then be removed andreplaced individually, as required.

As discussed above, the fingers 1560 of the hand assembly 1024 come intocontact with objects frequently and are, therefore, susceptible to wear.Thus, referring to FIG. 67, some embodiments of the present inventionmay include a cosmesis 1566 for covering the hand assembly 1024 toreduce wear of the hand assembly 1024 and the fingers 1560, inparticular. The cosmesis 1566 may be formed from silicone or a similarmaterial, such as a urethane, to improve the grip capabilities of thehand assembly 1024 to assist with the various grasping and pinchfunctions of the hand, thereby, providing additional functionality.

In use, the cosmesis 1566 may wear more quickly around the fingers 1560and the thumb structure 1220. Therefore, in some embodiments thecosmesis 1566 may separate into two or more sections to allow high wearareas to be replaced more frequently than low wear areas. For instance,referring to FIG. 68A, in some embodiments, the cosmesis 2566 includes aseparate palm section 2568 covering the hand support 2218, fingersections 2570 covering each finger 2560 and a thumb section 2572covering the thumb structure 2220. Thus, the finger sections 2570 andthumb section 2572 may each be replaced separately from the palm section2568. Although shown as having separate finger sections 2570 and thumbsection 2572, in various embodiments, the cosmesis 2566 may also includeonly two sections, for example, the finger sections 2570 and the thumbsection 2572 may be combined into one section and the hand support 2218may be covered by the separate palm section 2568.

Referring to FIG. 68B, in some embodiments of the present invention, thefingers 3560 may be provided with geometric features 3574, such asslots, in their outer surfaces 3576 that may accept correspondinggeometric interlocks 3578 provided on the inner surface 3580 of thecosmesis 3566. This interlocking geometry may resist shear loads on thecosmesis 3566, thereby preventing the cosmesis 3566 from slipping off ofthe fingers 3560. Additionally, with respect to the hand cosmesis, finepinch and other functions may require a structural backing at the tipsof the fingers 3560 and thumb structure 3220. Therefore, in someembodiments, the geometric features 3574 of the fingers 3560 and thumbstructure 3220 may each include a fingernail apparatus 579, shown inFIG. 40. The fingernail apparatus 579, shown in FIG. 40, interacts withthe finger and thumb structure cosmesis 3566 to anchor the cosmesis 3566of the fingers 3560 and thumb structure 3220, thereby mitigating and/orpreventing the cosmesis 3566 from rolling over on the tips of thefingers 3560 and thumb structure 3220.

Referring to FIG. 69, the palm section 1568 of the cosmesis 1566 mayalso be formed to resist slippage due to shear loads. For instance, apalm side 1582 of the cosmesis 1566 may be formed with a tacky innersurface 1584. In some embodiments, the material of the cosmesis 1566itself will provide the tacky inner surface 1584, for example, siliconeor a urethane material may be naturally tacky. In other embodiments, atacky surface coating may be applied to the cosmesis to form the tackyinner surface 1584. Thus, as objects being held are pressed against thepalm side 1582 of the cosmesis 1566, the tacky inner surface 1584 ispressed against the hand support 218, shown in FIG. 29, therebyresisting slippage. In some embodiments, a back side 1586 of thecosmesis 1566 is formed with a slippery inner surface 1588 to facilitateinstallation and removal of the cosmesis 1566. For example, the slipperyinner surface 1588 may be formed by applying a surface modifying coatingto the cosmesis, or applying a surface texture to the cosmesis 1566. Forexample, to install the cosmesis 1566 onto the hand support 218, shownin FIG. 29, the cosmesis 1566 may be pulled down and away from the palmso that the slippery inner surface 1588 of the back side 1586 slidesalong the hand support 218, while the tacky inner surface 1584 of thepalm side 1582 is pulled away from the hand support 218. Thus, thecosmesis 1566 may be easily slid onto the hand support 218. To removethe cosmesis 1566, the palm side 1582 may again be pulled away from thehand support 218 while the cosmesis 1566 is pulled toward the fingers1560, thereby allowing the cosmesis 1566 to slide easily off the handsupport 218.

Referring to FIG. 70, in some embodiments, the cosmesis 4566 may includecorrugations 4812 having grooves 4814 wherein a thickness of thematerial forming the cosmesis 4566 is substantially less than thethickness of material of the rest of the cosmesis 4566. The corrugations4812 and grooves 4814 may advantageously be positioned in locationswhere the prosthetic arm apparatus 10, shown in FIG. 1, moves and flexesto allow the cosmesis 4566 to flex along with the arm movement withoutbunching, wrinkling, tearing or the like. Additionally, although thecorrugations 4812 are shown only in a wrist area for simplicity, itshould be understood by those skilled in the art that the corrugations4812 may be positioned in other locations where substantial movement isanticipated such as the fingers. In some embodiments, the cosmesis 4566may also include raised ridges 4816 having a material thickness that isgreater than substantially the rest of the cosmesis 4566 to provideimproved grip in desired regions such as at the fingertips of thecosmesis 4566.

Referring to FIG. 71, in some embodiments, the fingers 1560 may includeone or more additional functions. For example, one or more fingers 1560may include a thermal sensor 1590 disposed thereon to determine thetemperature of an object (not shown) brought into contact with thefinger 1560. The signal from the sensor 1590 may be transmitted to acontroller (not shown) for the prosthetic arm 1010 and displayed to theuser as will be discussed in greater detail below. In some embodiments,temperature detection may be provided by forming the cosmesis 1566, or aportion thereof, from a temperature sensitive polymer, such as a polymerwith a thermochromic color changing additive therein or thermochromicliquid crystal that allows a variety of colors to be shown astemperature changes, which will change color depending upon thetemperature of the cosmesis 1566. For example, the cosmesis 1566 maychange from one color to another if a present temperature is exceeded.This temperature sensing functionality may be used to determine thetemperature of an object (not shown) in the hand 1024 and to warn theuser of a high temperature or low temperature condition to mitigate thethreat of burns or other harm.

Referring to FIG. 72A, another embodiment of the thumb structure 2220 isshown for providing thumb compliance detection. The thumb structureincludes a thumb base 2592 and a thumb tip 2594, which are eachsubstantially rigid and are joined together by an elastomeric spring2596. In some embodiments, the interface between the thumb tip 2594 andthe elastomeric spring 2596 includes one or more alignment features 2598to ensure proper alignment of the thumb tip 2594 with the elastomericspring 2596. Similarly, the interface between the thumb base 2592 andthe elastomeric spring 2596 also includes one or more alignment features2598 to ensure proper alignment of the thumb base 2592 and theelastomeric spring 2596.

Referring to FIG. 72B, within the thumb structure 2220, the thumb base2592 includes a pivotal interface tube 2600 extending upward into acentral bore 2602 of the elastomeric spring 2596. A pivot shaft 2604,having a magnet 2606 disposed at its lower end 2608, is arranged withthe pivotal interface tube 2600 and extends upwardly therefrom into acentral bore 2610 in the thumb tip 2594 of substantially the samediameter as the pivot shaft 2604. Below the pivot shaft 2604 within thethumb base 2592 is arranged a Hall effect sensor 2612 on a sensorbracket 2614. The sensor bracket 2614 includes a wire channel 2616 tofacilitate wiring the Hall effect sensor 2612 to the prosthetic controlcircuits (not shown). Referring to FIG. 72C, in operation, when a load Lis applied to the thumb tip 2594 the elastomeric spring 2596 compresseson the side of the thumb structure 2220 opposite the applied load L,allowing the thumb tip 2594 to tilt. The tilt of the thumb tip 2594causes a corresponding tilt of the pivot shaft 2604 within the pivotalinterface tube 2600, thereby displacing the magnet 2606 disposed on thelower end 2608 of the pivot shaft 2604. The Hall effect sensor 2612detects this displacement of the magnet 2606, which can be correlated tothe applied load L on the thumb tip 2594. By detecting the various loadson the thumb structure 2220, the user may ensure that objects are notgripped so hard that they could break and that the thumb is notsubjected to loads that could cause failure of the thumb structure 2220.

Referring to FIG. 73, wherein like numerals represent like elements,another embodiment of the thumb structure 3222 is shown for providingthumb compliance detection. In this embodiment, a helical spring 3597replaces the elastomeric spring 2596, shown in FIG. 72B, between thethumb base 3592 and the thumb tip 3594. Additionally, a collar 3599 isdisposed between the helical spring 3597 and the pivot shaft 3604 with asmall clearance between a ball 3605 of the pivot shaft and the collar3599. As with the previous embodiments, the pivot shaft 3604 has magnet3606 disposed at its lower end 3608 and extends upwardly therefrom intoa central bore 3610 in the thumb tip 3594 and is secured therein. Belowthe pivot shaft 3604 within the thumb base 3592 is arranged sensor 3612for detecting movement of the magnet 3606. In operation, when a load Lis applied to the thumb tip 3594, the ball 3605 contacts the collar 3599and the helical spring 3597 compresses on the side of the thumbstructure 3222 opposite the applied load L, allowing the thumb tip 3594to tilt about the center of the ball 3605. The tilt of the thumb tip3594 causes a corresponding tilt of the pivot shaft 3604, therebydisplacing the magnet 3606 disposed on the lower end 3608 of the pivotshaft 3604. The sensor 3612 detects this displacement of the magnet3606, which can be correlated to the applied load L on the thumb tip3594. By detecting the various loads on the thumb structure 3222, theuser may advantageously ensure that objects are not gripped so hard thatthey could break and that the thumb is not subjected to loads that couldcause failure of the thumb structure 3222.

Referring to FIG. 74, in some embodiments, the humeral rotator 1016 mayinclude a yolk 1618, rather than the cantilever mounting interface shownin FIG. 16, for interfacing with the elbow flexion assembly 1018. Theyolk 1618, interfaces with a first side 1620 and a second side 1622 ofthe elbow flexion assembly 1018 to provide increased strength to theinterface when compared to the cantilever mounting interface shown inFIG. 16, which only interfaces with one side of the elbow flexionassembly 1018.

Referring to FIG. 75A, in some embodiments of the present invention, theprosthetic arm 3010 may be provided with a status indicator 3620. Insome embodiments the status indicator 3620 may include, but is notlimited to, one or more LEDs 3622 arranged on the hand assembly 3024.However, in other embodiments, the one or more LEDs 3622 may be locatedin various locations. The one or more LEDs 3622 may be configured tocommunicate a variety of information to the user, including, but notlimited to, one or more of the following, battery power level, anoperational mode of the prosthetic device, faults, alarms, alerts,messages, and/or the like. Additionally, although shown as one or moreLEDs 3622 the status indicator 3620 may, in other embodiments, include adigital display and/or user interface, which may be arranged on theprosthetic device 3010, built into the prosthetic device 3010 and/or maybe a separate display unit (for example, as shown in FIG. 75B as 3630),and in some embodiments, may be a unit worn similarly to a wrist watchor bracelet as shown in FIG. 75B as 3630. However, in other embodiments,the unit 3630 may be a portable unit that may be worn or carried nearthe user, for example, but not limited to, clipped on clothing, beltand/or attached to the user, and/or carried in a pocket either in theuser's clothing and/or in a separate bag and/or pack. In someembodiments, the unit 3630 may be a PDA (personal data assistant), smartphone or other electronic device configured to communicate with theprosthetic device 3010 by way of a wireless communications protocol,including, but not limited to, RF and Bluetooth®.

Thus, in some embodiments, it may be desirable to include both aseparate display unit and one or more LEDs 3622, where, for example, butnot limited to, the one or more LEDs 3622 may be used to display one ormore critical piece of information to the user, while the separatedisplay unit, 3630 may provide a greater variety of information in moredetail.

Referring to FIG. 75C, an embodiment of the wrist rotator 4020 havingthe ACM stack 4128 housed therein is shown. The wrist rotator 4020includes a housing 4738 having an input interface 4739, such as theelbow interface 170, shown in FIG. 23, and an output interface 4740,such as the wrist flexion assembly interface 172, shown in FIG. 23, ateither end thereof. The housing also includes a user interface 4741formed therein and in communication with the ACM stack 4128. The ACMstack 4128 controls operation of each segment of the prosthetic armapparatus 10, shown in FIG. 1, including the wrist rotator 4020 and,therefore, integrating the ACM stack 4128 into the wrist rotator 4020may be advantageous since the wrist rotator 4020 is likely to be presentin prosthetic arms for essentially all types of amputees, whereas othersegments may not be present, such as in a prosthetic arm apparatus for atransradial amputee.

The user interface 4741 may include the status indicator 4620 forcommunicating status information of the prosthetic arm apparatus 10,shown in FIG. 1, from the ACM stack 4128 to the user. The user interface4741 may also include one or more user inputs 4742, such as buttons,switches, dials or the like for changing and/or customizing the statusinformation that is conveyed from the ACM stack 4128 through the statusindicator 4620.

The status indicator 4620 may include one or more LEDs 4622 configuredto communicate the status information from the ACM stack 4128 to theuser through illumination of the LEDs 4622. For instance, specificinformation may be communicated to the user through simple illumination,flashing patterns, color patterns and/or various combinations thereof.The LEDs 4622 may include a battery alert 4744 for alerting the user ofa low power condition. Similarly, the LEDs 4622 may include a systemalert 4746 for alerting the user of a system fault condition. The LEDsmay include a mode indicator 4748, for example, to indicate whether theprosthetic arm apparatus 10, shown in FIG. 1, is in mode for controllingarm movement or a mode for controlling hand movement. Additionally, theLEDs 4622 may include an array 4750 of LEDs 4622 for providing specificinformation to the user on the current operational mode of theprosthetic device. For instance, when in a hand control mode, each LED4622 in the array 4750 may represent a different sub control mode of theprosthetic device 10, shown in FIG. 1, such as different grip movements.In some embodiments, LEDs 4622 may be arranged at multiple locationsaround the circumference of the wrist rotator 4020 so that at least someof the LEDs 4622 remain visible to the user as the prosthetic arm 10,shown in FIG. 1, moves during operation.

Preferably, the user interface 4741 is formed from a rubberized materialto allow actuation of the one or more user inputs 4742 therethrough andto prevent contaminants such as dirt, dust, water and the like fromcontacting and damaging the wrist rotator 4020. Additionally, therubberized material preferably includes one or more translucent portions4752 in the region of the status indicator 4620 for allowing light fromthe LEDs 4622 to pass therethrough and may also include one or moresymbols printed on the translucent portions 4752 for conveying statusinformation to the user.

Referring to FIGS. 75D and 75E, as discussed above, the wrist rotator4020 having the ACM stack 4128 and the user interface 4741 is preferablya modular unit that may connect either to a transradial mount 4754 for atransradial amputee or the elbow flexion assembly 18, shown in FIG. 1,for a transhumeral or shoulder disarticulated amputees. To facilitatethe connection, the input interface 4739 includes a captive spannerscrew 4756 having male threads, an alignment pin 4758 and one or moretorque transmission pins 4760. The transradial mount 4754 (or the elbowflexion assembly 18, shown in FIG. 1) includes female threads forengaging the male threads of the captive spanner screw 4756, a left handalignment hole 4762, a right hand alignment hole 4764 and one or moretorque transmission holes 4766.

To assemble the wrist rotator 4020 to the transradial mount 4754 or theelbow flexion assembly 18, shown in FIG. 1, power and communicationwiring connections are first made between the parts. Then, the alignmentpin 4758 of the wrist rotator 4020 is registered in either the left handalignment hole 4762 or the right hand alignment hole 4764 of thetransradial mount 4754 (or the elbow flexion assembly 18, shown in FIG.1), depending upon whether the prosthetic arm apparatus 10, shown inFIG. 1, is to be a left-handed or right-handed prosthesis, respectively.A spanner wrench may then be used to engage the spanner screw 4756 andthread the male threads of the spanner screw 4756 into the femalethreads of the transradial mount 4754 (or the elbow flexion assembly 18,shown in FIG. 1). As the male threads engage the female threads, thetorque transmission pins 4760 engage the torque transmission holes 4766until the spanner screw 4756 is fully seated. This connectionadvantageously provides a universal interface between the wrist rotator4020 and either the transradial mount 4754 or the elbow flexion assembly18, shown in FIG. 1. The connection is also advantageously universal forboth left-handed and right-handed prosthetic devices. For example, theusing the right hand alignment hole 4764 provides for a desired range ofmotion for a right-handed prosthetic device, such as two hundred seventydegrees (270°). Using the left hand alignment hole 4762 provides a rangeof motion for a left-handed prosthetic device that is the mirroropposite of the range of motion for the right-handed prosthetic device,for example two hundred seventy degrees (270°) in the opposite directionof rotation. Additionally, when using either the left hand alignmenthole 4762 or the right hand alignment hole 4764 in the connection, theuser interface 4741 is advantageously maintained in the view of theuser.

Referring back to FIGS. 75A and 75B, in some embodiments of the presentinvention, the prosthetic arm 3010 may be provided with an emergencyswitch 3624 which may turn off power to the system and thus engage thevarious brakes and/or clutches in the prosthetic arm 3010. In someembodiments, the emergency switch 3624 is a chin switch that the usermay activate with their chin.

In some embodiments, another safety mechanism of the prosthetic arm 3010may include an auto release mechanism 3768 for manually opening a gripof the prosthetic hand 3024. The auto release mechanism 3768 may be abutton, switch or the like located on the back of the prosthetic hand3024, which, when actuated, causes the prosthetic hand 3024 to open.Preferably, the auto release mechanism 3768 is located under thecosmesis 1566, shown in FIG. 67, and actuated therethrough, to preventcontaminants such as dirt, dust, water and the like from contacting anddamaging the auto release mechanism 3768. The auto release mechanism3768 is electrically coupled to a power source (not shown) of theprosthetic arm 3010, such as a battery, and to motor control circuits,such as the hand control module circuit boards 192, shown in FIG. 25,that control actuation of the motors within the prosthetic hand 3024,such as the two thumb drives 232, the index drive 234 and the MRP drive236, all shown in FIGS. 31-34. Preferably, the auto release mechanism3768 is connected to the motor control circuits for the two thumb drives232, the index drive 234 and the MRP drive 236, all shown in FIGS.31-34, in parallel to provide redundancy to the auto release mechanism3768 so that even if one circuit fails, the others will still cause theassociated prosthetic fingers to open. In some embodiments, additionalredundancy may be provided to the auto release mechanism 3768 byconnecting the auto release mechanism 3768 to the motor control circuitboards 192 through at least two switches, with only one switch beingrequired to cause the prosthetic hand 3024 to open.

In operation, the user may depress the auto release mechanism 3768,which, in turn, actuates the switch or switches on the hand controlmodule circuit boards 192. Actuation of the switch or switches causespower to be supplied from the power source (not shown) to the two thumbdrives 232, the index drive 234 and the MRP drive 236, all shown inFIGS. 31-34, through the hand control module circuit boards 192, whichcauses the prosthetic hand 3024 to open. The speed at which theprosthetic hand 3024 opens may be tuned within the hand control modulecircuit boards 192 and is preferably less than approximately five (5)seconds. In some embodiments, the speed at which the prosthetic hand3024 opens may even more preferably be set to less than approximatelythree (3) seconds. Thus, the user may advantageously actuate the autorelease mechanism 3768 to release the grip of the prosthetic hand 3024if it is closed and/or becomes stuck in hazardous and/or harmfulsituations; for example, if the grip becomes stuck around a car doorhandle, a bus handle, while shaking a child's hand or any other similarsituation.

Although the auto release mechanism 3768 has been described as beingelectrically coupled to the power source (not shown) of the prostheticarm 3010 and to the hand control module circuit boards 192, in otherembodiments, the auto release mechanism 3768 may include a separatepower source (not shown) and/or separate motor control circuits (notshown) located within the prosthetic hand 3024 to provide additionalredundancy. Additionally, in other embodiments, the auto releasemechanism 3768 may be a mechanical system rather than an electricalsystem, for example, the auto release mechanism 3768 may be a crank orthe like for manually opening the prosthetic hand 3024.

The prosthetic arm apparatus of the present invention has a variety ofbenefits over conventional prosthetic devices, such as the modularity ofeach segment of the prosthetic arm apparatus as discussed above, whichallows the formation of customized prosthetic devices for differentusers. In particular, each segment of the prosthetic arm apparatus 10contains all of the actuators for that segment so that it may be removedas a separate unit. For instance, the hand assembly includes all of thefinger actuators therein, allowing it to be connected and/or removed asa separate unit. Additionally, various degrees of freedom of the handassembly are particularly beneficial because they allow the formation ofvarious grasps or grips.

Although the invention has been described in the context of a prostheticarm, an apparatus according to the elements of this invention could beused in other robotic tools, such as those used in manufacturing and/orteleoperations, where an operator is not connected directly to thecontrolled device. For example the prosthetic arm apparatus may be usedfor teleoperation in hazardous environments and/or hazardous activities,for the detonation of explosive devices or the like. In theseenvironments, the prosthetic arm apparatus may provide a more intuitiveinterface for the user since the user will already be familiar with thenatural movements of the arm, which may make control translation of theprosthetic arm apparatus easier.

Referring now also to FIG. 97, in some embodiments, a portion of theprosthetic arm attaches to a socket or other device to attach theprosthesis to a user. In some embodiments, the socket may be made usinga multistep procedure including, but not limited to, casting and/orcreating the socket which may include attaching a device that connectsthe socket to the prosthesis. In some embodiments, it may be desirableto use a method of casting/creating the socket that allows forflexibility and or options in the size and shape of the socket. This maybe desirable for many reasons, including, but not limited to, fittingthe socket to the user such that the socket is comfortable and conformswith the user's body.

Referring still to FIG. 97, in some embodiments, a frame 7800 or socketpreparation device (which may herein be referred to as a frame) asshown, may be used in creating the socket. The frame 7800 may include aplurality of legs 7802, 7804, 7806, 7808, 7810, 7812, 7814 orprotrusions, e.g., seven (7), to provide for flexibility in creating thesocket. In some embodiments, the number of legs may be seven (7), inother embodiments, the number of legs may be more than 7 and in someembodiments, the number of legs may be less than seven. In practice, aprosthetist, or other, may choose the appropriate legs 7802, 7804, 7806,7808, 7810, 7812, 7814 for the fit desired and may bend the chosen legse.g., one or more of 7802, 7804, 7806, 7808, 7810, 7812, 7814, to anappropriate shape and mount the legs 7802, 7804, 7806, 7808, 7810, 7812,7814 to a socket. Following, the prosthetist, or other, may remove(e.g., cut off) any unnecessary/unused legs. Thus, in some embodiments,the frame allows for a custom fit to the user. In some embodiments, theframe may be made from aluminum or another material that provides forthe desired result, for example, in some embodiments, the material maybe selected based on the weight to strength ratio as well as its abilityto bend without cracking or breaking. In some embodiments, the frame maybe made from 5052 aluminum, however, in other embodiments, differentgrades of aluminum and/or different materials (e.g. metals, plastics,composites, etc) may be used.

Still referring to FIG. 97, the frame 7800 includes a center portion7816 at which each leg 7802, 7804, 7806, 7808, 7810, 7812, 7814attaches. The center portion 7816 is the portion that will attach to aprosthetic mounting device (not shown, shown in FIGS. 98A-98C).

Referring now also to FIGS. 98A-98C and 99A-99D, the prosthetic mountingdevice 7820 may be attached to the frame. The frame center portion 7816includes a series of holes 7818 on the outside and a series (3 in theembodiment shown) of openings 7822 on the inside and a large opening7822 in the center. In some embodiments, the numbers of holes and/oropenings may be greater than or less than the numbers shown on thefigures. These openings 7818, 7822, and holes 7818 on the frame 7800correspond to openings and holes on the prosthetic mounting device. Asshown in FIGS. 99A-99D, the prosthetic mounting device 7820 attaches tothe frame 7800 and to the shoulder portion 7826 of the prosthesis. Thearrangements of both the holes and openings on the frame and the holesand openings on the prosthetic mounting device may be beneficial forvarious reasons, including, but not limited to, the ability to orientatethe frame with respect to the prosthetic mounting device and theprosthesis which may provide greater flexibility for custom fitting thesocket. In some embodiments, rotation of the frame with respect to theprosthetic mounting device provides +/−10 degree increments of rotation.In other embodiments, the spacing of the various holes and openings mayvary and/or the number and/or the location of holes and openings mayvary to provide various degrees of increments.

Referring now again to FIG. 98B, the some embodiments of the prostheticmounting device 7820 are designed to be bonded into the socket. Invarious embodiments, there is a groove 7828 and anti-rotation features7830 to connect, e.g. securely connect, to the socket. Using the frame7800 to position the prosthetic mounting device 7820 in the appropriatelocation prior to creating the final socket, the prosthetic mountingdevice may be beneficial for many reasons, including, but not limitedto, providing orientation for the socket.

In some embodiments, screws on the outside of the prosthetic mountingdevice function as pins to prevent rotation while bolts hold/secure theprosthetic mounting device to the prosthesis.

In some embodiments, once the prosthetic mounting device is attached tothe prosthesis, for example, as shown in FIG. 99D, the prosthesis may beremoved and the prosthetist may build up the socket. Finally, in someembodiments, the frame may be removed.

There are many advantages to the frame 7800 embodiments. These include,but are not limited to, one or more of the following. The frame 7800 maybe used to ensure the proper location of the prosthetic mounting deviceso that the socket may be registered. Also, the frame allows aprosthetist to position the mounting device, and tweak/adjust theprosthetic mounting device position, until the prosthesis is in thedesired anatomical position with respect to the intended user.

Referring now to FIGS. 100A-100F various views of a shoulderflexor-abductor are shown. In some embodiments, the shoulder may includea feedback flexor position sensor 7852 which may include a spiralsurface 7830 that ensures that for any position of the flexor, therewill be a different radius, which may be determined. Thus, in someembodiments, the shoulder may include a potentiometer, which may, insome embodiments, be similar to the potentiometers described above. Aturning shaft 7832 is connected to a potentiometer using a turning arm7834 and a preload spring 7836 keeps the turning arm 7834 preloaded inone direction. As the turning shaft 7832 spins with movement of theshoulder the flexor moves the spiral 7830 and the radius changes. Duringrotation, the resistance of the potentiometer is changed which may becorrelated with a position.

Referring also to FIGS. 101A-101D, in some embodiments, the shoulder mayalso include a braking mechanism 7854, which, in some embodiments, maybe a band brake including a brake band 7858, which stops both the flexorbrake rotor 7838 and abductor brake rotor 7840. In some embodiments, thebraking mechanism 7854 includes a band brake that is opened and closedby the brake motor 7860 and in some embodiments, a potentiometer 7856may be used to determine whether the braking mechanism 7854 is engagedor disengaged by measuring the brake shaft angle. An adjustment blockmay be used to properly position the brake band 7858 so the correcttension is achieved when the braking mechanism 7854 is engaged and insome embodiments, the potentiometer 7856 may be used for brake motor7860 control to engage and disengage the braking mechanism 7854 whichmay be desirable for many reasons, including, but not limited to,avoiding wearing out the rotors. In some embodiments, a currentthreshold (read by motor drive electronics) may be determined when aproper tension is achieved in the brake band 7858.

In some embodiments, the system may engage the braking mechanism 7854 ofthe shoulder and other joints with brakes in the system, when the systemdetermines that the motors do not need to turn, thus, in someembodiments, the braking mechanism 7854 may be engaged to preserve thebattery.

The shoulder brake may be closed or open and does not require power tomaintain the state (whether open or closed). Thus, the brake onlyrequires power to change the state from engaged to disengaged, andvice-versa.

Referring now to FIGS. 102A-102E, another embodiment of the abductorpotentiometer sensor system 7862 is shown. The abductor roller screw7844 shaft turns, which drives a nut, which opens the linkages whichpivots the shoulder about the abductor pivot pin. The position of theabductor roller screw 7844 is determined using the abductorpotentiometer sensor 7850. On the abductor roller screw shaft 7844 is aworm gear 7846. The worm gear 7846 mates with a worm wheel 7848. Theworm wheel 7848 is mounted to the abductor potentiometer sensor 7850. Insome embodiments this arrangement may be desirable/beneficial for manyreasons, including, but not limited to, in some embodiments, theabductor roller screw 7844 may experience multiple rotations to a singlerotation of the output shaft, for example, in some embodiments, theabductor roller screw 7844 may experience 16 rotations to a singlerotation of the output shaft, however, in various other embodiments, thenumber of rotations may be greater than or less than 16. Thus, in theseembodiments, reading the position of the abductor roller screw 7844directly may not yield the necessary information. Therefore, in variousembodiments, the rotations of the abductor roller screw 78434 are geareddown, i.e., the multiple rotations (e.g. 16 rotations) are geared downby a factor (e.g., 20 to 1). The gear down factor is determined in someembodiments by the gears used in the system through the variousembodiments. Thus, the gear down reads the rotation as less than 1rotation, e.g. ¾ of a rotation or (288 degrees), however, in variousother embodiments; this gear down factor may vary. Thus, the abductorpotentiometer sensor 7850 may, in some embodiments, only measure lessthan a full rotation. Therefore, the abductor potentiometer sensor 7850is reading a position intermediate within the power train; therefore, itis geared it down. There are many advantages to this system, including,but not limited to, the sensor measurement may occur on the same side asthe electronics. Therefore, elimination and/or minimizing the number ofwire wires over the moving joint.

Referring now to FIGS. 103A-103C, various views of the wrist are shown,including views including one embodiment of a wrist rotator sensor. Thewrist rotator sensor uses a potentiometer 7866 (which, in someembodiments, is a variable resistance potentiometer) and as a plunger ismoved around the resistance is changed. In some embodiments, the wristrotator sensor is integrated directly onto the circuit board 7864 whichmay be desirable for many reasons, including but not limited to, thatthe wrist rotator sensor is a single unit and may be “dropped into” thewrist rotator. In some embodiments, the design of the wrist rotatorsensor includes alignment portions/features 7868 which may be desirablefor many reasons, including, but not limited to, in manufacture, where,in some embodiments, the wrist rotator sensor may not be able to beassembled into the wrist unless aligned properly.

Also, in some embodiment, the wrist rotator sensor includes where theplunger 7870 is integrated into the sensor assembly and the plungerflexor spring 7872 pushes the plunger onto the sensor

Referring now also to FIGS. 104A-104B, in some embodiments, the wristalso includes an external position sensor/potentiometer for the wristflexion joint. In some embodiments, the external position sensorincludes gears, including a sector gear 7074, a potentiometer gear 7076,which, including a potentiometer 7078, provide variable resistance basedon position. In some embodiments, the external position sensor alsoincludes alignment features on the output shaft 7080, sector gear 7082and potentiometer gear 7084 to ensure the arrangement/alignment iscorrect. This sensor may be desirable for many reasons, including, butnot limited to, that the positioning of the wrist is smooth, reliableand accurate, and consistent and less sensitive to temperature. Thissensor may also be desirable for its ability to maintain/hold aposition. The sensor may also be desirable for it requires a smallamount of power (only when resistance reading) and therefore may improvebattery life. In various embodiments, the sensor is a passive sensori.e., the sensor does not require being powered up for use. The sensoris a resisting element.

In various embodiments, a system and method for battery charging isincluded. In various embodiments, a system may include at least oneinternal battery, and at least one external battery. However, in someembodiments, the system may include at least one external battery but nointernal battery. In still other embodiments, the various embodiments ofthe system may include one or more external batteries. In variousembodiments, the internal battery is located inside a device, which, insome embodiments, may include a prosthetic device. The at least oneinternal battery, in some embodiments, may not be readily accessibleand/or directly accessible by a user. For example, in some embodiments,the at least one internal battery may be located in the device such thatthe battery housing is waterproof and/or protected from the outerenvironment and therefore, not accessible unless a plate and/or abattery cap and or other is first removed. In various embodiments, theat least one internal battery may be a rechargeable battery andtherefore, in some embodiments, it may be desirable to recharge thebattery from an external source rather than removing thenot-readily-available internal battery to recharge the internal battery.In some embodiments, where the at least one internal battery may bereadily accessible, it may be desirable to recharge the internal batteryfrom at least one external source. In some embodiments, the at least oneexternal source may include, but is not limited to, one or more of thefollowing: at least one external battery and/or at least one AC adapter.In some embodiments, the at least one AC adapter may be a medical gradeAC adapter, for example, a 60 watt XP Power AC adapter, model numberAFM60, made by XP Power Limited, Singapore. In some embodiments, the ACadapter may be 24 VDC. However, in various embodiments, a different ACadapter or other adapter or outside charging device may be used. In someembodiments, the at least one AC adapter may be connected to the deviceto charge the at least one internal battery by connection to a chargingport. In some embodiments where the device is a prosthetic arm device,the charging port may be located anywhere on the device, including butnot limited to, on the forearm.

In some embodiments, the internal battery may be a 4S1P lithium-ionrechargeable 18650 cells battery for a nominal voltage of 14.8 VDChaving 2 amp hours of capacity. However, in various other embodiments,the internal battery may be a larger or smaller voltage with more orless capacity. In some embodiments, the at least one internal batterymay include a SMBus gas gauge IC and protection circuitry.

In some embodiments, the system may include no external batteries.However, in some embodiments, the system may include at least oneexternal battery. In some embodiments, the at least one external batterymay be used to power a device, for example, but not limited to, aprosthetic device. In some embodiments, the at least one externalbattery may be used to recharge an internal battery in a device. Forexample, in some embodiments, the at least one external battery may beused to recharge a non-removable internal battery in a device. In someembodiments, the at least one external battery may be a 4S2P lithium-ionrechargeable 18650 cells battery for a nominal voltage of 14.8 VDC and 5amp hours of capacity. In some embodiments, the at least one externalbattery may include a SMBus gas gauge IC and protection circuitry. Insome embodiments, the system may include one external battery and insome embodiments, the system may include two or more external batteries.In some embodiments, the at least one external battery may be worn by auser by attaching the external battery to a holster, a belt holster, apack or other apparatus to secure the external battery to the user. Insome embodiments, the external battery is connected to a device, forexample, but not limited to, a prosthetic device, by an electricconnector, for example, a cable.

In some embodiments where at least one external battery is used, a powerbutton may be located on the holster or other holder of the externalbattery. In an exemplary embodiment, the holster may be configured toinclude a pushbutton holster (e.g., in some embodiments, this embodimentmay be used when there is no internal battery) or a non-pushbuttonholster (e.g., in some embodiments, this embodiment may be used whenthere is at least one internal battery). In some embodiments where bothat least one internal battery and at least one external battery areincluded in the system, the internal battery includes an internalbattery interface. In these embodiments, software is common to both theinternal battery interface and the holster and configuration jumpers onthe board may be read by the software to determine the type of board.

In various embodiments, the system may include a device, including, butnot limited to, a medical device, e.g., a prosthetic device orprosthetic arm; at least one internal battery and at least one externalbattery. In some embodiment of this embodiment, the system may includeat least two external batteries. In some embodiments, all the batteriesmay include built-in circuits for measuring state-of-charge andprotection against faults. In some embodiments, one or more batteriesmay include built-in circuits for measuring state-of-charge andprotection against faults. In some embodiments, similar to other “smart”batteries, the batteries may communicate this information to the systemusing the System Management Bus (SMBus) hardware/software protocol. Insome embodiments, the at least one or at least two external batteriesare charged by an external battery charger.

In some embodiments, as discussed above, a holster may be includedwherein the holster accepts and secures the external battery. Referringnow also to FIG. 105, one embodiments of a battery interface, view intoholster or charger, is shown. In various embodiments, when one externalbattery is mounted in the holster, spring contacts in the holster mateto metal pads on the external battery, which interfaces the battery tothe device's, e.g., prosthetic arm's, power and communication busses.The external battery charger duplicates the holster's interface to thebattery for both supplying charge power and for SMBus communication.

Referring also to FIG. 106, one embodiment of a holster 7082 and anexternal battery 7084 is shown. Referring also to FIG. 107, in someembodiments, a charger 7088 may accommodate one or more externalbatteries 7084, 7086. In the embodiment shown in FIG. 107, the charger7088 accommodates two external batteries 7084, 7086.

In some embodiments, the external battery charger 7088 may be designedto charge up to two external batteries 7084, 7086 simultaneously. Insome embodiments, for ease of use, the external batteries 7084, 7086 maybe loaded vertically—like a toaster—relying on the battery's weight, insome embodiments, to create sufficient force to connect with theelectrical contacts. In some embodiments, the external batteries 7084,7086 may include a keying feature 7090, i.e., they may be keyed, toprevent being inserted backwards. In some embodiments, each charger bay7092, 7094 may have a dedicated charge circuit; both of which, in someembodiments, may be overseen by a microcontroller with custom software.

In some embodiments, bulk power may be supplied to the battery charger7088 by an off-the-shelf medical-grade power supply that produces 24VDC. In some embodiments, this power may be the AC adapter describedabove, i.e., the same power supply that may be used to provide chargepower to the device.

In some embodiments, the external battery charger 7088 is a Level 3charger by the definitions of the Smart Battery System specification.Thus, the charger's 7088 microcontroller acts as the SMBus master, andqueries each battery for its desired charging current and terminalcharging voltage. The microcontroller forwards this information to thecharge circuits. The microcontroller may provide the full requestedcharge power, or limit one or both batteries to avoid exceeding therating of the power supply. Through the SMBus interface, the charger7088 may also be able to query the external batteries' 7084, 7086 statusand use this information to determine if a fault has occurred.

The interactions among the external batteries 7084, 7086, the chargecircuits, and the microcontroller are complex. In general, the softwareand hardware are architected to disable power to the charging circuitsby default. In some embodiments, only when a number of predeterminedconditions are met (for example, but not limited to, one or more of thefollowing: charge voltage in acceptable range, battery is present andcommunicating, battery reports no faults, requested charge current inacceptable range, etc.) will charge power be applied.

Referring now also to FIG. 108, a system block diagram of one embodimentof the battery system for a device is shown. As discussed above, in someembodiments, various embodiments of the battery system may be used witha prosthetic device, including, but not limited to, a prosthetic arm.However, in various embodiments, the various embodiments of the batterysystem may be used with any device requiring power. For purposes ofillustration only, some embodiments of the system are described withreference to a prosthetic arm. However, this is for descriptive purposesonly and it should be understood that the system is not limited to usewith a prosthetic arm. In various other embodiments, the componentsdescribed below with reference to a prosthetic arm, e.g., “shoulder ACMstack”, may be different where the system is used in conjunction with adevice other than a prosthetic arm device.

Referring now also to FIG. 109 and FIG. 110, diagrams of two embodimentsof the internal battery interface are shown. In some embodiments, wherethe system includes an internal battery and at least one externalbattery, the internal battery connects to a custom circuit board calledthe internal battery interface. This board contains a microcontrollerthat talks e.g. on a CAN bus as a slave, to a master controller. Theboard also has a charging circuit for the internal battery. The chargingcircuit is powered, in some embodiments, from either an external 24 VDCpower source (like from an AC adapter) or from the system power bus(getting power from the external battery). Because in some embodimentsthe 24 VDC AC adapter interface connector may be a common barrelconnector, to reduce and/or eliminate the possibility that a user mightconnect the wrong voltage AC adapter and to protect against the wrongvoltage or polarity AC adapter from affecting the internal batteryinterface electronics, in some embodiments, circuitry may beincorporated into the internal battery interface board to tolerate arange of AC adapter input voltages, for example, including, but notlimited to, a range from −36 VDC to +36 VDC. In various otherembodiments, this range may be different. In some embodiments, thevoltage range may be determined by conducting a search of commonlyavailable AC adapters with similar output connectors.

In some embodiments, the internal battery interface circuitry mayinclude a soft power interface controller. In some embodiments, thiscontroller monitors the power on/off button, and helps to control systempower. In some embodiments, the microcontroller also participates inthis functionality; however the soft power controller may, in someembodiments, independently shut off the system power if themicrocontroller fails to respond to power off requests.

Referring now also to FIG. 111 and FIG. 112, diagrams of two embodimentsof the external battery interface with a holster are shown.

In some embodiments, the external battery connects to another customcircuit board in the external battery holster, which is described inmore detail below. In some embodiments, the schematic for the externalbattery holster board may be similar to the schematic of the internalbattery interface board. In some embodiments, the schematic for theexternal battery holster board may be different from the internalbattery interface board. In some embodiments, the external batteryholster contains a microcontroller that talks, e.g. on a CAN bus as aslave, to the master controller, and it talks to the internal batteryover a SMBus.

In some embodiments, the external battery interface circuitry includes asoft power interface controller. In some embodiments, this controllermonitors the power on/off button, and helps to control system power. Aswith the internal battery interface board, in some embodiments, themicrocontroller may also play a part in this functionality, however thesoft power controller may independently shut off the system power shouldthe microcontroller fail to respond to one or more power off requests.In some embodiments, the soft power controller in the holster 7082 isonly installed when there is a pushbutton in the holster 7082.

Referring now also to FIG. 111, a system schematic of one embodiment ofthe system is shown. In this embodiment, the system includes an internalbattery and at least one external battery. Again, referring to aprosthetic arm for illustration purposes, inside the prosthetic forearm,in some embodiments, an internal battery circuit board is located nextto the internal battery. The internal battery circuit board includes amicrocontroller that communicates with the internal battery includingcommunications related to the charge of the internal battery. Inaddition, in some embodiments, the microcontroller communicates with theprosthetic arm systems communication bus (CAN Bus) which communicateswith the master controller. The master controller, therefore, in variousembodiments, receives information about the battery, which may include,but is not limited to, the amount of charge in the battery. The mastercontroller can make decisions regarding when to charge the internalbattery and also, when to switch between the external battery and theinternal battery for powering the device, e.g., the prosthetic arm. Theexternal battery also has an interface board with a microcontroller thatcommunicates to the external battery and the arm system's communicationsbus (CAN bus), which communicates with the master controller. In someembodiments, a cable connects the external battery to the arm/devicesystem. The power from the external battery may also power thearm/device.

In some embodiments, the internal battery circuit board includes a smartcharger circuit that may either accept input power from the AC adapteror from the arm system power bus, thus charging the internal batteryfrom the external battery. In some embodiments, the power from the powerbus (which comes from the external battery) is boosted to a highervoltage for input to the smart charger.

The following are various methods that may be applied by the system todetermine where to take power from, e.g., which battery to take powerfrom, to power the device. These are not limiting factors andadditional/alternative factors may be used in various embodiments. Insome embodiments, one or more of the following are not used.

In some embodiments, whenever there is an external battery connected tothe system, the master controller decides that the external batterypowers the bus and therefore, disconnects the internal battery from thepower bus.

In some embodiments, when the external battery remaining capacity goesbelow a preset/predetermined/preprogrammed threshold, the mastercontroller may automatically command the internal battery to switch topower the bus.

In some embodiments, alerts and warnings may be displayed to the user(for example, using a user interface on the device) if the installedbattery, i.e., the combined remaining capacity of all installedbatteries, is below a preset/predetermined/preprogrammed threshold.Thus, in various embodiments, to determine the combined capacity/totalcapacity of all installed batteries, the total capacity of all internalbatteries, and any external battery connected to the system, is used.

In some embodiments, where there is an internal battery and the devicesystem first powers on, the system may always be initially powered bythe internal battery until the master controller determines how manybatteries are connected, for example, whether there is an externalbattery present.

In some embodiments, once the device power is turned on, the maincomputer/master controller determines whether there is an externalbattery present. If there is an external battery present, but if it isnot connected, the master controller will allow the internal battery topower the bus.

However, in some embodiments, once the master controller determines thatthere is an external battery present, the master controller determinesif the external battery has enough capacity, i.e., the external batterycapacity exceeds a predetermine/preset/preprogrammed threshold, and ifso, connects the external battery to the power bus and disconnects theinternal battery from the power bus.

In some embodiments, the interface board near the internal battery maymonitor the status of that internal battery to determine whether theinternal battery needs to be charged, i.e., whether the capacity of theinternal battery is less than a preset/preprogrammed/predeterminedthreshold. When an external battery is present and has greater than apreset/predetermined/preprogrammed threshold of remaining capacity,then, in some embodiments, the interface board may begin charging theinternal battery using the external battery.

In some embodiments, connecting the AC adapter to the device takespriority over charging the internal battery from the external battery.This may be beneficial for many reasons, including, but not limited to,preserving the power that is in the external battery.

In some embodiments, the external battery, which, in some embodiments isalso rechargeable, may be required to be removed/disconnected from thedevice and/or from the holster to be charged. Thus, in some embodiments,the external batteries will not recharge if connected to the device/arm.

As described above, some embodiments of the system include an externalbattery holster 7082. In these embodiments, the external battery holster7082 may include contacts that allow the external battery 7084 to beunclipped from the holster 7082. In some embodiments, the holster 7082may have a microcontroller, in some embodiments having amicrocontroller, when the external battery 7084 is taken off the holster7082 or is not connected to the holster 7082, the device/system maydetermine that the holster 7082 is still connected but that the externalbattery 7084 is no longer connected to the holster 7082. In someembodiments, where the device previously determined that two batteries,an internal and an external, are connected, the device can determinethat the external battery 7084 has been disconnected. In someembodiments, when the external battery 7084 is disconnected from theholster 7082 the device/arm may automatically switch over to use theinternal battery to power the device/arm. In some embodiments, thesystem may determine that the external battery 7084 is disconnected bymonitoring the falling voltage.

In some embodiments, when the system first turns on, the circuit in theinterface circuit closes and powers the bus. Then the master controllersees the external battery 7084 and turns the holster 7082 on and theinterface circuit off and then the external battery 7084 powers the bus.

In some embodiments, when the external battery 7084 is disconnected fromthe holster 7082, the external battery 7084 may reach apreset/predetermined/preprogrammed hot swap “threshold voltage” and thesystem may then turn on the internal battery interface circuit and turnoff the holster 7082/external battery interface circuit.

Next, in some embodiments, if a new, for example, charged externalbattery is inserted into the holster 7082, the holster 7082 interfaceknows that an external battery has been connected to the system, and, insome embodiments, the master computer then turns the holster7082/external interface circuit on and the internal battery interfacecircuit off.

Thus, in some embodiments, the system includes a method and system for“hot swapping” a battery/power source that is powering a device. In someembodiments, for example, having a device including at least oneinternal battery and two external batteries, where the device is poweredby the external battery and the system determines that the externalbattery becomes disconnected, the system may continue regular operationby turning the external interface circuit off and the internal interfacecircuit on, thereby continuously powering the device. Then, when, forexample, the external battery is connected again to the system/device,the system recognizes that the external battery is again connected andturns the internal interface circuit off and the external interfacecircuit on, thereby the device is powered again by the external battery.

In some embodiments, this method may be used to “hot swap” a firstexternal battery for a second external battery. In some embodimentsthese may be beneficial for changing external batteries when oneexternal battery's charge has depleted and a second external battery ismore charged than the first. For example, in some embodiments, where thefirst external battery has been powering the device for a thresholdperiod of time which may be close to the maximum use, a user may hotswap the first external battery for a second external battery which maybe, in some embodiments, fully charged. This may be beneficial forcontinuously powering the device without interruption.

In some embodiments, for example, in embodiments where the system isused with a medical device, for example, a prosthetic device, which mayinclude a prosthetic arm, the system allows for functionality of thedevice/arm using an internal battery, which may be supplemented by anexternal battery. Therefore, for example, where a user may bedressing/undressing, using the internal battery during this time allowsfor arm functionality without being tethered to an external battery by acable. The tethering and/or cable may make tasks, for example,dressing/undressing, more difficult. However, this system allows for useof an external battery, which may have longer use per charge, and also,for a hot swap of the external battery. The system also includes theability to recharge the internal battery using the external batterywhich provides for a system of assuring the user that the internalbattery will be charged when next needed, for example, if morning tasksdepleted the internal battery charge by 75%, once connected to theexternal battery, for example, during the daytime hours, the internalbattery will be recharged to 100% from the external battery. Then, forevening tasks, for example, which may include those tasks that are moreconvenient to accomplish without a tether to an external battery, theinternal battery will be available/charged. This system is advantageousfor many reasons, including, but not limited to, providing ease ofrecharging the internal battery, continuous use of the device even whileswapping power sources, and allowing for use of the device/arm for taskswhere being tethered or having cables may inhibit/make difficult one'sability to complete the desired tasks efficiently and/or with ease. Invarious embodiments, the AC adapter may be used, for example, overnight,to charge the internal battery while the charger may be used to chargethe one or more external batteries.

In various embodiments, the user interface on the device may indicate tothe user the charge status of the one or more batteries, i.e., internaland/or external battery, connected to the device/arm. For example, insome embodiments, the wrist display may indicate the total amount ofremaining capacity which is calculated based on the total batteriesconnected to the system, e.g., in some embodiments, 1 battery or 2batteries. Therefore, in these embodiments, if 2 batteries are connectedto the system, the battery indicator adds the total capacity of bothbatteries and determines the remaining capacity. Thus, for example, ifno external battery was connected to the device, and the internalbattery is 100% charged, the user interface may indicate that the chargeis 100%. However, if an external battery is then connected to thesystem, and it is not itself 100% charged, the user interface batteryindicator may indicate less than 100%, taking into consideration theamount of charge remaining on both batteries. Thus, this may beadvantageous for many reasons, including, but not limited to, the systemreporting an accurate remaining capacity to the user taking intoconsideration all the batteries connected to the device.

Although this system has been described with respect to prostheticdevices, in some embodiments, the system may be used in any deviceincluding, but not limited to, those devices where the internalrechargeable battery is not user replaceable or where the internalrechargeable battery is difficult to replace and/or remove to recharge.In some embodiments, the system may be used on any device that is aportable continuous duty system where it is desirable that the devicecontinuously be powered on to perform one or more tasks. In someembodiments, the system may be used with a medical device.

In various embodiments, the hot swap described above may be used once anexternal battery is disconnected and an AC adapter is connected. Thus,once the system determines that the external battery is disconnected,the system switches to using the internal battery. Following, once theAC adapter is connected to the device, the system switches to using theAC adapter to charge the internal battery. Also, vice-versa, where theAC adapter is currently connected and is then disconnected and anexternal battery is connected, the internal battery will be charged fromthe external battery.

The system may be used in many devices including, but not limited to,infusion pumps, monitoring device and other device having a high dutycycle. The various embodiments of the systems includes one or more powersources, which may include one or more, but not limited to, thefollowing: AC adapter, rechargeable battery internal to the device,rechargeable battery external to the device, and where one of thesepower sources is powering the device, another of these power sources maybe connected to the device and henceforth power the device.Additionally, one or more of the power sources may recharge one or moreof the other power sources, for example, an external battery mayrecharge an internal battery and/or an AC adapter may recharge aninternal battery. In some embodiments, while the device is currently inuse and powered by an external device, the external device may alsoprovide charge to an internal battery to recharge the internal battery.

Thus, in some embodiments of the system, the external battery not onlyruns the device, but also, recharges the internal battery at the sametime, and can swap out the external battery for with a second externalbattery when the first external battery's charge is depleted. All ofthese may be accomplished while the device is fully powered in acontinuous, uninterrupted manner.

In various embodiments, the system may be advantageously used in deviceswhere it may be beneficial for the device not to be plugged in, and/ornot be tethered, for example, but not limited to, laptops and/orsurgical devices.

In some embodiments the system may be advantageous in devices whereremoving the internal battery may interrupt the ongoing use of thedevice and/or trigger a start up process which would interrupt theperformance of a device.

In some embodiments, the system may include methods for hot swapping twoor more batteries that may be user accessible. For example, the systemmay include a first battery and a second battery. The first battery maybe 100% charged and the second battery may be 50% charged, or in variousembodiments, the first battery may be more charged than the second. Thefirst battery may charge the second battery while the first batterypowers a device. Thus, in some embodiments, a first battery may serve asa charger battery and a second battery may serve as a charged battery.In some embodiments, once the first battery/charger battery is depletedof its charge to a preset/threshold/predetermined/preprogrammed level,the second battery/charged battery may be swapped out automatically suchthat the second battery/charged battery is now running the device andfirst battery/charger battery is being recharged by the second battery.Thus, the first battery and the second battery swap tasks. Thus, in someembodiments, this method provides that one battery is always morecharged than a second battery and therefore, the device may becontinuously powered without interruption and/or without restartingand/or starting up processes.

In some embodiments, the various hot swap methods may include methodsfor increasing the life of the battery by not exceeding apreset/predetermined minimum charge, e.g., 50%. In some embodiments, thesystem may favor maintaining the internal battery at a charge as high aspossible.

Referring now to FIGS. 114A-114F, in some embodiments the shoulder mayinclude a braking apparatus or system, which, in some embodiments, maybe a caliper braking apparatus or system 11400. In some embodiments, thebraking apparatus or system may be used in other applications, otherthan the shoulder of a prosthetic arm. FIGS. 114B-114D are views ofembodiments of a caliper braking system, including a cam rod 11402 foractuating the calipers of the caliper braking system 11400. The cam rod11402 may include cam surface disposed towards one end of the cam rod11402. The cam surface may include a first actuation portion 11412 and asecond actuation portion 11414, the second actuation portion 11414 beingsubstantially wider than the first actuation portion 11412. In someembodiments, the cam surface may gradually increase in width around thecircumference of the cam rod. Starting with the first actuation portion11412, the cam surface profile may increase in width around the cam rodcircumference and end with the second actuation portion 11414. In someembodiments, the cam rod 11402 may be actuated by a motor 11419.Further, in some embodiments, the cam rod 11402 may be actuated by themotor 11419 by way of a clutch assembly 11420 as seen in FIG. 114D. Theclutch assembly 11420 may transfer the rotational power from the motorto the cam rod and further may avoid malfunctions and failures of thecaliper braking system 11400 by absorbing unwanted axial forces exertedthrough the motor.

The calipers of the braking system, in some embodiments, may include afirst caliper 11406, and a second caliper 11404. The first caliper 11406may further include a first cam actuation surface 11410. Similarly, thesecond caliper 11404 may further include a second cam actuation surface11408. The first cam actuation surface 11410 and the second camactuation surface 11408 may be configured to engage the cam surface ofthe cam rod 11402 such that, as the cam rod 11402 is actuated, the firstand second cam actuation surfaces may transition from being in contactwith the first actuation portion 11412 of the cam surface to being incontact with the thicker, second actuation portion 11414 of the camsurface. As the second actuation portion 11414 comes into contact withthe first and second cam actuation surfaces, it will move the first andsecond cam actuation surfaces, and thus the first and second calipers,substantially away from each other, as seen in FIG. 114E.

In some embodiments, the caliper braking system 11400 may include a biasmember 11403, as seen in FIGS. 114B and 114C. The bias member 11403 maybe engaged with the first caliper 11406 and the second caliper 11404such that the bias member encourages the first and second caliperstowards each other. Thus, as the cam rod 11402 is actuated, and thesecond actuation portion 11414 of the cam surface comes into contactwith the first and second cam actuation surfaces of the first and secondcalipers, respectively, the first and second calipers will movesubstantially away from each other, against the encouragement of thebias member 11403.

Referring now to FIGS. 114E and 114F, in some embodiments, the first andsecond calipers may be configured to engage a first and second brakerotor, respectively. The first and second brake rotor may beconcentrically aligned to each other such that they have a concentriccenter of rotation to each other. The first and second brake rotors mayalso be adjacently disposed. The first caliper 11406 may have a firstengagement portion 11418 that is configured to engage with the firstbrake rotor 11426. Similarly, the second caliper 11404 may have a secondengagement portion 11416 that is configured to engage with the secondbrake rotor 11428. In the resting state of the calipers, the bias member11403 encourages the calipers in a direction substantially towards eachother so the first engagement portion and the second engagement portionengage with the first and second brake rotors, respectively, such thatbrake rotors are prevented from freely rotating due to circumferentialfriction on each rotor by the respective engagement portion. When thecam rod 11402 is actuated, the first and second calipers movesubstantially away from each other, as mentioned above. This actioncauses the first engagement portion and the second engagement portion todisengage from the first and second brake rotors, respectively, as seenin FIG. 114E, thereby allowing the brake rotors to move freely.

In some embodiments, the first and second calipers and their respectivefirst and second rotor engagement portions may be configured such thatthe first caliper 11406 will only engage the first brake rotor 11426,and the second caliper 11404 will only engage the second brake rotor11428. In other words, the first and second brake rotors may be orientedconcentrically to each other, yet they each will be engaged by theirrespective caliper separately, as seen in FIG. 114F. This configurationwill allow the first and second brake rotor to differ in diameter andstill be able to effectively engage with their respective first andsecond calipers.

Referring now to FIGS. 115A-B, in some embodiments the hand may includean index pivot assembly or system 11500. The index pivot assembly 11500may include an index base assembly 11502, an index member assembly11504, a threaded pivot shaft 11506, and a pivot retention assembly11508 which, in some embodiments, may be retained in the index baseassembly 11502 by at least one fastening member 11514. In someembodiments, the at least one fastening member 11514 is a screw.Further, the index member assembly 11504 may include a pivot groundelement 11516 that is rotatably disposed within the index memberassembly 11504 such that the index member assembly 11504 is free torotate relative to the pivot ground element 11516. In some embodiments,one or more bushings 11520 may be disposed in between the index memberassembly 11504 and the pivot ground element 11516 in order to facilitaterotational movement and to reduce the amount of wear between the indexmember assembly 11504 and the pivot ground element 11516.

The index member assembly 11504 may be pivotably attached to the indexbase assembly 11502 by inserting the threaded pivot shaft 11506 into theindex base assembly 11502 and through the pivot ground element 11516 andhaving the pivot ground element 11516 fixed in the index base assembly11502 by the pivot retention assembly 11508. The pivot ground element11516 may be fixed in the index base assembly 11502 such that the pivotground element 11516 cannot rotate relative to the index base assembly11502, while maintaining the rotational freedom of movement of the indexmember assembly 11504 relative to the pivot ground element 11516, andthus, the index base assembly 11502.

The pivot retention assembly 11508 may, in some embodiments, include aretention base 11510 and a plurality of compression members 11512. Thepivot retention assembly 11508 may be engaged with the threaded pivotshaft 11506 such that when the threaded pivot shaft 11506 is tightened,the pivot retention assembly 11508 exerts radially compressive force onthe pivot ground element 11516 so that the pivot ground element 11516 isfixed in the index base assembly 11502 and cannot rotate relative to theindex base assembly 11502. In some embodiments, the threaded pivot shaft11506 is threaded into the pivot retention assembly 11508 and the pivotretention assembly 11508 exerts the radially compressive force on thepivot ground element 11516 when the threaded pivot shaft 11506 istightened. In some embodiments, the threaded pivot shaft 11506 isthreaded into the retention base 11510 to accomplish exerting theradially compressive force on the pivot ground element 11516. In someembodiments the compression members 11512 may be wedge shaped andinterface with the retention base 11510, the pivot ground element 11516,and a plurality of inclined surfaces 11518 in the index base assembly11502. Upon tightening the threaded pivot shaft 11506, the retentionbase 11510 may urge the wedge-shaped compression members 11512 along theinclined surfaces 11518 such that the inclined surfaces 11518 move thecompression members 11512 in a direction towards the pivot groundelement 11516 so that the compression members 11512 exert a radiallycompressive force on the pivot ground element 11516. In someembodiments, there may be two wedge-shaped compression members 11512,and the inclined surfaces 11518 may be facing each other, such that theyurge the two compression members substantially towards one another sothat they exert a radially compressive force on two respective points ofcontact on the pivot ground element 11516 that are substantiallyopposite from one another. Referring now to FIGS. 116A-B, in someembodiments, the hand may include a compliance assembly 11600. Thecompliance assembly 11600 may include an index finger structure 11614being driven through an index sun shaft 11602, a set of index planets11604, an index planet carrier 11606, and an index ring gear 11608. Theinterior teeth of the index ring gear 11608 may operatively engage eachplanet of the index planet set 11604, the rotation of the index planetset 11604 rotating the index planet carrier 11606. The index fingerstructure 11614 may be driven by the exterior teeth of the index planetcarrier 11606, which is driven by the rotation of the index planet set11604 due to the operative engagement of each planet of the index planetset 11604 with the interior teeth of the index ring gear 11608.

The rotation of the index planet carrier 11606 may be slower than thatof the index ring gear 11608 due to a gear reduction function carriedout by the rotation of the index planet set 11604. Torque may betransmitted from the index finger structure 11614 through the indexplanet carrier 11606 and index ring gear 11608 to the index sun shaft11602 when there is a load on the index finger structure 11614. Theindex planet carrier 11606 may be axially supported by way of an indexpin 11612 and an index pin bushing 11610, the pin 11612 being radiallysupported by the bushing 11610. The index pin 11612 may be coaxial withthe index sun shaft 11602, and the index pin 11612 may reduce the amountof unwanted bending forces experienced by the index sun shaft 11602 fromthe index planet carrier 11606 by acting independently of the index sunshaft 11602.

While the principles of the invention have been described herein, it isto be understood by those skilled in the art that this description ismade only by way of example and not as a limitation as to the scope ofthe invention. Other embodiments are contemplated within the scope ofthe present invention in addition to the exemplary embodiments shown anddescribed herein. Modifications and substitutions by one of ordinaryskill in the art are considered to be within the scope of the presentinvention.

What is claimed is:
 1. A brake apparatus for a prosthesis, the brakeapparatus comprising: a first caliper configured to operatively engagewith a peripheral edge of a first brake rotor; a second caliperconfigured to operatively engage with a peripheral edge of a secondbrake rotor, the second brake rotor configured to rotate concentricallyto the first brake rotor; wherein the first and second calipers areengaged with the peripheral edges of the first and second brake rotorssuch that the first and second brake rotors are prevented from rotatingwhen the first and second calipers are in a locked position; and anactuation mechanism configured to move the first and second calipersfrom the locked position to an unlocked position; wherein the first andsecond brake rotors can freely rotate when the first and second calipersare in the unlocked position.
 2. The brake apparatus of claim 1, furthercomprising a bias member operatively engaged with both the first andsecond calipers such that the first and second calipers are biasedtowards the locked position.
 3. The brake apparatus of claim 2, whereinthe actuation mechanism comprises a cam rod including a cam surface, thecam surface operatively engaged with both the first and second calipers,such that when the cam rod is actuated, the cam surface urges the firstand second calipers to move against the bias member to the unlockedposition.
 4. The brake apparatus of claim 3, wherein the actuationmechanism further comprises a motor configured to actuate the cam rod.5. The brake apparatus of claim 4, wherein the actuation mechanismfurther comprises a clutch operatively engaged with the motor and thecam rod, such that the motor actuates the cam rod through actuation ofthe clutch.
 6. The brake apparatus of claim 1, wherein the first caliperis configured to engage the first brake rotor independent from thesecond brake rotor, and the second caliper is configured to engage thesecond brake rotor independent from the first brake rotor.
 7. The brakeapparatus of claim 6, wherein the first brake rotor and the second brakerotor each have a different diameter from each other.
 8. The brakeapparatus of claim 1, wherein the first brake rotor is concentricallyaligned and adjacent to the second brake rotor.